AWX2-SER Rev A Service Manual Models: 1.0, 1.3, and 1.5 WARNING This manual must only be used by a qualified heating installer / service technician. Read all instructions, including this manual and the Armor X2 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........................................................................ Hazard Definitions .............................................................. PLEASE READ BEFORE PROCEEDING ......................... Handling Ceramic Fiber Materials ...................................... When servicing water heater ........................................ Water heater operation ................................................ Heater water ..........................................................
Service Manual Please read before proceeding WARNING Installer – Read all instructions, including this manual and the Armor X2 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 X2 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 c
Service Manual 1 Service The Armor X2 display 5
Service Manual 1 Service Control inputs SECONDARY SMART CONTROL MODULE LOW VOLTAGE CONNECTION BOARD PRIMARY SMART CONTROL MODULE SEQUENCER / BUILDING MANAGEMENT SYSTEM HW TANK SENSOR O-TEMP HEAT EXCHANGER SWITCH PRIMARY/SECONDARY INLET TEMPERATURE SENSOR ENABLE O-TEMP HEAT EXCHANGER SWITCH PRIMARY/SECONDARY OUTLET TEMPERATURE SENSOR FLOW SWITCH BLOCKED DRAIN SWITCH FLOW SWITCH TOUCH DISPLAY PRIMARY/SECONDARY FLUE GAS SENSOR TOUCH PANEL INTERFACE PRIMARY/SECONDARY HIGH LIMIT SENSOR PRIMARY
Service Manual 1 Service (continued) Control outputs LOW VOLTAGE CONNECTION BOARD SECONDARY SMART TOUCH CONTROL MODULE PRIMARY SMART TOUCH CONTROL MODULE ALARM BELL RUN TIME CONTACTS HEAT EXCHANGER 1 / HEAT EXCHANGER 2 HW PUMP SEQUENCER / BUILDING MANAGEMENT SYSTEM TOUCH DISPLAY TOUCH PANEL INTERFACE IGNITOR PC INTERFACE BLOWER GAS VALVE 7
Service Manual 1 Service General Operation How the water heater operates Access modes The Armor X2 uses two (2) advanced stainless steel heat exchangers and two (2) electronic control modules that allow fully condensing operation. The blowers pull in gas and air and push flue products out of the water heater through the heat exchangers and flue piping. The control modules regulate blower speeds to control total water heater firing rate.
Service Manual 1 Service (continued) Sequence of operation Table 1A Sequence of operation Note: This unit is equipped with two (2) independent, but synchronized combustion systems. One of the heat exchanger combustion systems will fire first. If the demand cannot be met by one (1) combustion system the same sequence of operation will be followed to bring the second heat exchanger combustion system online. 1. Upon a call for heat, the control turns on the appropriate pumps. 2.
Service Manual 1 Service Parameter table Table 1B This table lists the parameters and where to access them SETUP SERVICE / SETUP PARAMETERS SET POINT PARAMETERS 10 USER ACCESS INSTALLER ACCESS SEE PAGE DISPLAY MODIFY DISPLAY MODIFY Service/Setup 17 Yes Yes Yes Yes Night Setback 17 Yes Yes Yes Yes Set points 17 Yes Yes Yes Yes Cascade 17 Yes Yes Yes Yes BMS 17 Yes Yes Yes Yes Demand Conf 18 Yes No Yes No Serv Not Time 18 No No Yes Yes Serv Not Run H 18
Service Manual 1 Service (continued) BMS CASCADE NIGHT SETBACK Table 1B (continued from previous page) This table lists the parameters and where to access them Date and time 21 Yes Yes Yes Yes On Timer and Off Timer 21 No No Yes Yes Casc Address 22 Yes Yes Yes Yes Casc off df 22 No No Yes Yes Casc off/on df 22 No No Yes Yes Max Outl temp 22 No No Yes Yes BMS Type 23 No No Yes Yes ModBus Timeout 23 No No Yes Yes BMS Setp min V 23 No No Yes Yes BMS
Service Manual 1 Service Viewable and changeable control parameters Status Screen: When the ON/OFF switch is turned to the ON position, the first screen visible on the LCD display will be the Status Screen. This screen displays the current status of the Armor X2 water heater. The following items can be viewed or interacted with on the Status Screen: On/Off button - Pressing this button allows the water heater to be placed in either Manual Shutdown Mode or Standby Mode.
Service Manual 1 Service (continued) Configuration - This line shows the current configuration of the two control modules inside the unit. Outlet Water Temperature - This is a calculated temperature based on the readings of the outlet temperatures of the two (2) heat exchangers. Inlet Water Temperature - This is a calculated temperature based on the inlet temperature readings from the two (2) heat exchangers.
Service Manual 1 Service Details Screen: The Details Screen is accessed by pressing the DETAIL button on the Status Screen. This screen shows the status of the various safeties, inputs and outputs to each control module. Selection of the control module to be viewed is accomplished by pressing the SELECT button. The control module being displayed is shown in the module box. Displayed items are as follows: • HW Thermostat - Is ON when a Hot Water call has been received from a tank thermostat.
Service Manual 1 Service (continued) A blank message box is located on the Details Screen. This box will display various messages detailing the status of the control module. If a message is present in this box, the DETAILS button on the Status Screen will contain a yellow triangle with an exclamation mark (!) inside. Displayed items are as follows: • Delta T Shutdown - The temperature rise between the inlet and outlet temperatures has exceeded 35°F.
Service Manual 1 Service Main Screen: The Main Screen allows navigation to eight (8) additional screens which are used to set temperatures, operating conditions, and monitor water heater operation. These screens are as follows: • Setup - Allows access to five (5) other screens for the adjustment of the control parameters. • Cascade - Shows the status of multiple heaters connected together in a cascade arrangement.
Service Manual 1 Service CAUTION (continued) Before changing parameters, note the settings so that the unit can be returned to its original operating parameters. Setup Screen: The Setup Screen allows access to five (5) other screens for adjusting control parameters. These screens are as follows: • Service / Setup - Allows access to change service notification parameters, LCD backlight parameters, and temperature units. • Setpoints - Allows access to change the HW set point and ON/OFF differentials.
Service Manual 1 Service Service/Setup Parameters Screen: The Service / Setup Screen allows access to 10 parameters. Those parameters are as follows: • Demand Configuration - Sets the configuration of the control modules inside the water heater. The configuration selections are: Demand Configuration 1: Cascade Set Point Thermostat based - the control modulates the water heater based on the user set point and the temperature of the tank sensor.
Service Manual 1 Service (continued) • Maximum Service Time - Service Mode allows the installer to control the fan speed of the individual control modules for the purposes of combustion analysis. Service Mode will override all other heat demands, however, all safeties will remain intact. Maximum service time sets the length of time the water heater will stay in Service Mode if no buttons are pressed before reverting back to its original state. This parameter can only be changed by the installer.
Service Manual 1 Service Set Point Parameters Screen: The Set Point Screen allows access to 6 parameters. Those parameters are as follows: • Hot Water Tank Set Point - The hot water tank set point sets the target temperature of the water in the tank. This parameter can be changed by the user or the installer. The temperature range of this parameter is 60° to 185°F. The default value is 125°F.
Service Manual 1 Service (continued) Night Setback Parameters Screen: The Night Setback Screen allows access to 15 parameters. Those parameters are as follows: • 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 heater is first installed or any time the heater has been powered off for more than 30 days.
Service Manual 1 Service Cascade Parameters Screen: Cascade Operation When multiple water heaters are installed, they can be wired together in a cascade sequence. A maximum of eight (8) heaters can be controlled from a single control. In this application one heater would be designated as the Leader and all others would be designated as Members. The designated Leader water heater determines the total output needed from the group based on the set point and the tank sensor reading.
Service Manual 1 Service (continued) 0 - 10Vdc BMS Parameters Screen: 0-10Vdc Operation When the Demand Configuration parameter (see page 18) is set to either Cascade BMS Thermostat Based, Cascade BMS Voltage Based, Cascade Modbus BMS Thermostat Based, or Cascade Modbus BMS Voltage Based; a 0 - 10Vdc signal can be supplied to the terminal strip connection or through Modbus communications to control a single unit or a multiple unit cascade. The BMS Screen allows access to 12 parameters.
Service Manual 1 Service • BMS Modulation at Minimum Voltage - Determines the modulation rate of the unit or cascade when the BMS input voltage is at or below the setting of the BMS Voltage at Minimum Modulation parameter. This parameter is only active when the BMS Type is set to modulation rate. This parameter can only be changed by the installer. The range of this parameter is 0% to 100%. The default value is 14.5%.
Service Manual 1 Service (continued) Cascade Screen: The Cascade Screen provides the status of the cascade system. Items that can be viewed on the Cascade Screen are as follows: Water Heater Power Level Indicators - For each water heater present in the cascade a power level indicator will be present above its corresponding number. The level will rise and fall indicating the approximate power level of the water heater.
Service Manual 1 Service 1 On 34 80 55 The Building Screen displays information that is specific to the Building Automation System and is being transmitted through the Modbus communication link: Modbus Address - This is the address of a specific Armor X2 water heater. This address is set by dip switches on the Modbus communication board. The value displayed here should be the same as the value of the dip switches.
Service Manual 1 Service (continued) Temps Screen: The Temps Screen displays the various temperatures as measured by sensors connected to each control module. Items that can be viewed on the Temps Screen are as follows: • Inlet 1-2 - This is the water temperature as measured by the sensor located in the inlet of each heat exchanger. • Outlet 1-2 - This is the water temperature as measured by the sensor located in the outlet of each heat exchanger.
Service Manual 1 Service Burners Screen: This screen provides the status of the combustion air blowers and flame signals. Items that can be viewed on the Burners Screen are as follows: • Blower Power Level Indicator - Two (2) blowers are depicted on the display. The top blower corresponds with Heat Exchanger 1 or Top heat exchanger. The lower blower corresponds with Heat Exchanger 2 or Bottom heat exchanger. Beside each blower is a power level indicator.
Service Manual 1 Service (continued) Graph Select Screen: The Graphs Screen consists of two (2) different screens. The first screen is the Parameter Selection Screen. By pressing the box beside the desired item, a check will appear in the selected box and the control will graph the status of that item. A maximum of five (5) items can be graphed at one time. The second screen is accessed by pressing the NEXT button. Once the items to be graphed are selected, press the NEXT button to view the graph.
Service Manual 1 Service History Screen: The History Screen shows the status of various counters and faults for each control module. Selection of the control module to be viewed is accomplished by pressing the SELECT button. The control module being displayed is shown in the module box. Items that can be viewed on the History Screen are as follows: • Successful Ignitions - Shows the number of times the control has successfully ignited.
Service Manual 1 Service (continued) Service Mode Screen: The Service Mode Screen allows the individual control modules to override all other heat demands and operate at a full fire condition for the purpose of combustion analysis. Selection of the control module to be placed into Service Mode is accomplished by pressing the SELECT button. The control module being placed into Service Mode is shown in the module box. To place the unit into Service Mode, press the ON/OFF button until ON is displayed.
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; • Check water heater area Daily • Clean condensate trap and fill with fresh water • Check pressure/temperature gauge • Check for leaks (water, gas, flue, condensate) • Verify flue and air lines in good condition and sealed tight
Service Manual 2 Maintenance WARNING (continued) Follow the service and maintenance procedures given throughout this manual and in component literature shipped with the water heater. Failure to perform the service and maintenance could result in damage to the water heater or system. Failure to follow the directions in this manual and component literature could result in severe personal injury, death, or substantial property damage.
Service Manual 2 Maintenance 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 (continued) Inspect ignition and flame sense electrodes 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. Replace ignition/flame sense electrode, making sure gasket is in good condition and correctly positioned. Check ignition ground wiring 1.
Service Manual 2 Maintenance Cleaning water exchanger heater heat 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 heater in the Armor X2 Installation and Operation Manual. • Do not drain the heater unless it will be exposed to freezing temperatures. 2.
Service Manual 3 Troubleshooting Alarm Screen: If a fault occurs which requires a Manual Reset, the unit will go into a lockout condition and the Alarm Screen will be activated. The screen will switch between a black or red background every 5 seconds with the text “Alarm Unit Needs Servicing” shown on the display. A message box shows the alarm status of the two (2) control modules. Mod1 is for Control Module 1 and Mod2 is for Control Module 2.
Service Manual 3 Troubleshooting WARNING 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 except for momentary testing as outlined in the Troubleshooting chart.
Service Manual 3 Troubleshooting (continued) Table 3A Troubleshooting Chart - No Display FAULT CAUSE - No 120 VAC supplied to unit. CORRECTIVE ACTION • Check external line switch, fuse, or breaker. • Check position of ON/OFF switch. Turn switch to the ON position. • Check 120 VAC through the ON/OFF switch. • Check wiring harness connection between display board and main control board. Connect harness at both points. No Display - No voltage through the switch. • Replace switch. - Bad display board.
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. Table 3B - Inlet/Outlet and Tank Sensor Resistance vs.
Service Manual 3 Troubleshooting (continued) Table 3D Troubleshooting Chart - Noisy System FAULT CAUSE CORRECTIVE ACTION - Supply gas problem. Natural gas pressures • Refer to Section 7 - Gas Connections of the Armor X2 should be between 4 inches w.c. (1.0 kPa) Installation and Operation Manual for detailed and 14 inches w.c. (3.5 kPa). LP gas information concerning the gas supply. pressures should be between 8 inches w.c. (2.0 kPa) and 14 inches w.c. (3.2 kPa).
Service Manual 3 Troubleshooting Table 3E Troubleshooting Chart - Fault Messages Displayed on Water Heater Interface FAULT DESCRIPTION CORRECTIVE ACTION • Check water heater pump operation on a call for heat. Flow Switch/ LWCO Either the flow switch or the optional AUX (will require a manual switch is not making. reset once condition has been corrected. Press the RESET button on the display to reset.) Blown fuse.
Service Manual 3 Troubleshooting (continued) Table 3E (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Water Heater Interface FAULT DESCRIPTION CORRECTIVE ACTION • 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.
Service Manual 3 Troubleshooting Table 3E (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Water Heater Interface FAULT DESCRIPTION CORRECTIVE ACTION • 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.
Service Manual 3 Troubleshooting (continued) Table 3E (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Water Heater Interface FAULT DESCRIPTION CORRECTIVE ACTION Automatic Reset 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.
Service Manual 3 Troubleshooting Table 3E (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Water Heater Interface FAULT DESCRIPTION Blower RPM’s Too High CORRECTIVE ACTION • Vent/air intake lengths exceed the maximum allowed lengths. Refer to Section 3 - General Venting of the Armor X2 Installation and Operation Manual for proper lengths.
Service Manual 3 Troubleshooting (continued) Table 3E (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Water Heater Interface FAULT DESCRIPTION Air pressure switch contacts are open. CORRECTIVE ACTION • Check the wiring connections to switch. Wires should be connected to the common and normally closed terminals. • Vent/air intake lengths exceed the maximum allowed lengths.
Service Manual 3 Troubleshooting Table 3E (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Water Heater Interface FAULT DESCRIPTION CORRECTIVE ACTION Internal Fault The main control board has detected an • Replace the main control board. internal fault. Writing to Memos The main control board has detected an • Replace the main control board. internal fault. CRC Parameters The main control board has detected an • Replace the main control board. internal fault.
Service Manual 3 Troubleshooting (continued) Combustion Analysis Procedure Table 3H 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 sensors from the flue pipe connections. 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. Propane CO2 O2 CO2 O2 8.0% - 10% 3.0% - 6.5% 9.0% - 11% 4.
Service Manual 3 Troubleshooting Gas valve adjustment procedure Models 1.3 - 1.5 If adjustment of the gas valve is deemed necessary, use the following procedures: (Note: The procedures below are model specific.) Locate the throttle adjustment screw on top of the gas valve, see FIG. 3-3. Using an Allen wrench, turn the screw a 1/4 turn counterclockwise to increase CO2 levels or a 1/4 turn clockwise to decrease CO2 levels.
Notes 51
Revision Notes: Revision A (ECO #C09645) initial release.
