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Armor Wall Mount Service Manual

1. Freeze Protection Burner Differential Tank Set Point Yes Yes Yes Yes Tank Set Point Offset Yes Yes Yes Yes Tank Set Point Differential Yes Yes Tank Minimum Set Point Anti Cycling Override Differential Yes Yes Tank Maximum Set Point Anti Cycling Time ANTI DATA CYCLING DHW SETTINGS FUNCTIONS LOGGING 12 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 16 a ii No Yes Yes Yes Yes Description BMS Tstat Input lt Op O Q us C n als Z O k k hk k k k h k h k ok 00 oe 00 00 N N N N N N NIN Z O h O Z O ModBus T O k O Z O O O O Z O CONTROL MODES G Cascade Address No Yes Cascade Type No No Max Cascade Set Point 17 No No Yes Yes Min On Off Time 17 No No Yes Yes Min Next On Time Z O eS e lt lt a2 Z O ziz O O i e2 Boiler Size es e z O DHW Pump Delay No No Yes Yes Ee s DD ie DHW Pump Anti Seize Delay Yes Yes O BMS Type Power Set Point No No Yes Yes Volts at Min No Yes Yes Volts at Max No No Yes Yes Rate at Min Volts Z O Z O eS eS Rate at Max Volts Z O Z O Yes Yes Set Point at Min Volts Z O O eS eS Set Point at Max Volts Z O Z Yes Yes No No Yes Yes Off Differential Volts Installer Name and
2. Service Manual 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 ARNING 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 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 Address reported problems l Inspect any problems reported by the owner and correct before proceeding Inspect water heater area l Verify that water heater area is free of any combustible materials gasoline and other flammable vapors and liquids Verify that air intake area is free of any of the contaminants listed in Section 1 of the Armor Wall Mount Installation and Operation
3. Startup of the Installation and Operation Manual Replace the access cover and restore water heater to operation Service Manual Table 2B Heat Exchanger Cleaning Kits Component ieee Hane Number Description 1 4 x 24 Drill Extension KIT30063 125 200 A CAUTION Po NOT use a metal brush Only use the kit provided brush or an equivalent replacement nylon brush Figure 2 3 Rope Gasket Heat Exchanger Door ROPE GASKET CAUTION IF GASKET IS DAMAGED AZ DO NOT REUSE THE HEAT EXCHANGER DOOR ji MUST BE REPLACED Rope gasket is intended for sealing combustion NOTICE see FIG 2 3 If gasket is damaged DO NOT reuse the heat exchanger door must be replaced Consult factory for replacement heat exchanger door kit WTR3080 and WTR3086 Check Delta T 1 Check the Delta T using Table 2C as a reference Table 2C Water Heater Pump Applications Recommended Temperature Rise Water Heater Pump Applications Flow Rate Loss Temp GPM FT HD Rise 18 F Oiled bearing circulators 1 The circulator shipped with the water heater is water lubricated No oiling is required 2 Check other circulators in the system Oil any circulators requiring oil following circulator manufacturer s instructions Over oiling will damage the circulator 23 3 Troubleshooting A WARNING 22 all wires prior to disconnection when servicing controls Wiring errors can cause improper and dang
4. 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 e Check wiring harness connection at the gas valve and at the main control board e Inspect spark electrode and associated wiring for damage and connection Reference page 22 of this manual for removal and cleaning procedures Replace if necessary 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 Wall Mount 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 No Flame correctly and there are no obstructions Running will require a manual reset once the condition has been corrected 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 Press the RESET button on the SMART SYSTEM display to reset lf 24 VAC is present at the main
5. Verify that the vent air intake lengths do not exceed the maximum listed in the General Venting section of the Armor Wall Mount Installation and Operation Manual Gas air mixture problem Noisy Operation e Refer to page 22 in this manual for the burner removal and inspection procedure Clean or replace the burner as necessary Dirty damaged burner e Refer to Section 6 System Piping of the Armor Wall Mount Installation and Operation Manual for minimum flow rates Low water flow through the heat exchanger Air in the piping system e Properly purge all air from the piping system Low system water pressure e Verify system pressure is a minimum of 12 PSI No Pump Faulty pump e Replace pump Operation Faulty pump relay e Replace pump relay e Replace fuse F1 on the control board see page 24 of this manual e Replace main control board Internal fault on control board SGAE System pressure exceeds relief valve Lower the system pressure below the 150 PSI rating of Opening setting the supplied relief valve Service Manual 3 Troubleshooting Table 3F Troubleshooting Chart Fault Messages Displayed on Water Heater Interface FAULT DESCRIPTION CORRECTIVE ACTION e Check water heater pump operation on a call for heat e Check for closed valves or obstructions in the water heater piping Flow Switch will require a manual ENED The flow switch is not making been co
6. and main control board Connect harness at both points No voltage through the switch e Replace switch Bad display board e Replace board Bad main control board e Replace the main control board Blown fuse e Replace fuse F3 on the main control board see page 24 of this manual No Display Main control board temperature set point e Review temperature setting satisfied Te IUIIEEE Remote thermostat satisfied e Review remote thermostat setting Operation e Consult display for specific fault Refer to fault Unit locked out on fault descriptions on pages 28 35 of this manual for corrective actions Water heater controlled by BMS e Check BMS parameter settings Optional PC software required Unit Does Not Modulate Above 50 Flue sensor open e Verify that the flue sensor is located in the flue outlet e Check wiring connections at the flue sensor e Check the resistance of the flue sensor and compare to Table 3D on page 26 of this manual 25 E 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 r
7. beginning of the menu listings after entering the installer access code SHUTDOWN gt GEHERAL Rotate the NAVIGATION dial counterclockwise until DATA LOGGING FUMCTIOWS the arrow gt is next to DHW SETTINGS DHL SETTINGS HOME 47 SCROLL SHUTDOWN DATA LOGGING Press the NAVIGATION dial one time FUNCT LOM S DHL SETTINGS HOME sa SCROLL Rotate the NAVIGATION dial counterclockwise until coe cee i TAHE SP DIFF the arrow gt is next to TANK MIN SETPT STAG REL SETes HOME 44 SCROLL Press the NAVIGATION dial one time The TANK j j j TANE SF D MIN SETPT setting will begin to flash STHUe HIN SET HOME a7 SCROLL Rotate the NAVIGATION dial to the desired CTAN TANE MIH SETPS HOME 47 SCROLL SHUTDOWN TANE MIH SETP 10 F HOME S7 SCROLL SAVE SHUTDOWN Press the LEFT SELECT soft key EXIT if more Seater changes are to be made FUNCT IOWS DHL SETTINGS Select SAVE Press the RIGHT SELECT soft key SAVE one time EXIT ELT HOME SAVE When finished making changes press the LEFT Baranerere Pane SELECT soft key HOME uploading eee 11 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 RE See Description Pade ge Display Modify Display Modify Ki e gt 4 r Freeze Protection Pump On Yes Freeze Protection Burner On 15 Yes Yes GENERAL
8. control board check the wiring between the main control board and the gas valve Replace the wiring if necessary 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 e Replace the main control board J 30 p Service Manual 3 Troubleshooting continueg Table 3F continued from previous page Troubleshooting Chart Fault Messages Displayed on Water Heater Interface FAULT DESCRIPTION CORRECTIVE ACTION Flame Sequence e Check supply voltage for proper polarity will require a manual reset once the condition has been corrected Press the RESET button on the SMART SYSTEM display to reset e Check external wiring for voltage feedback The flame detector circuit is seeing a flame e Check the flame rod and make sure it is clean signal while no flame is present e Check the internal wiring for bad connections e Replace main co
9. 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 is set by the Set Point at Maximum Volts parameter The minimum value is the Set Point at Minimum Volts setting and the maximum is 190 F 88 C The default value is 180 F 82 C On Volts When programmed for BMS control through the 0 10V BMS input or through ModBus and the BMS Thermostat Input is set to INACTIVE the On Volts parameter 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 Off Differential Volts When programmed for BMS control through the 0 10V BMS input or through ModBus and the BMS Thermostat Input is set to INACTIVE the Off Differential Volts parameter determines how far below the On Volts setting 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 The default value is 1 0V Service Notification 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 the Service Notification in Months param
10. from the display panel Quick start information parameter table e An index of available adjustments and readouts where to access them and where to find detailed information Armor wall mount operation General e Data Logging e Functions e DHW Settings e Anti Cycling e Control Modes e Circulation Pumps e BMS e Service Notification Service Manual Maintenance e Service and maintenance schedules e Address reported problems Inspect water heater area and water heater interior e Clean condensate trap e Check all piping for leaks e Check air openings Flue vent system and air piping e Check water system e Check water heater relief valve Inspect ignition electrode e Check ignition ground wiring e Check all water heater wiring e Check control settings Perform start up and checks e Check burner flame e Check flame signal e Check flue gas temperature e General maintenance e Review with owner e Cleaning the water heater heat exchanger e Oiled bearing circulators Troubleshooting Troubleshooting table No display e Checking temperature sensors e Sensor tables e Troubleshooting table Fault messages displayed on the water heater interface e Combustion analysis procedure e Gas valve adjustment procedure ARMOR service Manual 1 Service The Armor wall mount display NAVIGATION DIAL PRESS OR TURN RESET KEY STANDBY foo TANK 125 F 130 J LEFT SELE
11. pump if connected will run after a DHW demand has been satisfied This parameter is adjustable by the installer by accessing the DHW Pump Delay parameter The time range for this parameter is 10 seconds to 40 minutes The default time is 1 minute DHW Pump Anti Seize Delay 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 the DHW Pump Anti Seize Delay parameter The range of this setting is 0 seconds to 50 minutes The default setting is 20 seconds BMS BMS Type 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 the BMS Type parameter 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 the Volts at Minimum parameter 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 Maximum value The default setting is 2 0V Volts at Maximum When programmed for BMS control through the 0 10V BMS input or through ModBus the Volts at Maximum parameter should be set to the maximum voltage signal sent to the SMART SYSTEM control Th
12. the Armor Wall Mount Installation and Operation Manual 2 Maintenance continued Flue vent system and air piping ie 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 Verify that water heater vent discharge and air intake are clean and free of obstructions A WARNING Failure to inspect for the above conditions and have them repaired can result in severe personal injury or death Check water system l Verify all system components are correctly installed and operational Verify system pressure is at least 12 PSI 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 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 l 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 Wall Mount Installation and Operation Manual for suggested best location of expansion tanks and air eliminators Check water heat
13. 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 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 21 2 Maintenance 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 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 con
14. CTED KEY RIGHT SELECTED KEY SOFT KEY SOFT KEY ee 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 Service Manual 1 Service Control inputs GAS PRESSURE SWITCH DHW THERMOSTAT LOW VOLTAGE CONNECTION BOARD FLOW SWITCH TANK SENSOR BUILDING MANAGEMENT SYSTEM LOW WATER CUTOFF INLET TEMPERATURE SENSOR OUTLET TEMPERATURE P NN HIGH LIMIT SENSOR FLUE GAS SENSOR SMART SYSTEM CONTROL MODULE PC INTERFACE Service Manual 1 ServiCe continued Control outputs ALARM BELL LOW VOLTAGE CONNECTION BOARD LOUVER RELAY 7 RUN TIME CONTACTS BUILDING MANAGEMENT SYSTEM BUILDING RECIRCULATION PUMP WATER HEATER PUMP IGNITOR Kr BLOWER SMART SYSTEM s CONTROL MODULE aE GAS VALVE C Jo DISPLAY PANEL Sf PC INTERFACE 7 1 Service General Operation How the water heater operates The Armor wall mount 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 amoun
15. ESET key to reset the service notification counter Installer Name and Phone Number NOTICE Please note that the brackets denote screen Status 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 the Service Name and Phone Number parameter When selected another menu will appear with PHONE and NAME l 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 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 3 Repeat this procedure until the entire message is entered If you make a mistake and wish to back up one character rotate the NAVIGATION dial until the back arrow lt character is displayed and press the NAVIGATION dial 4 When finished press the RIGHT SELECT SAVE key to return to the previous menu Service Manual 2 Maintenance Maintenance and annual startup Table 2A Service and Maintenance Schedules Service technician Owner mai
16. M display e If 120 VAC is present on a call for heat and the water to reset heater pump is not operating replace the pump e 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 e If the manual reset high limit has tripped check setting of the device e Check resistance of water sensors and compare to Table 3C on page 26 of this manual Replace sensor if necessary E gt Service Manual 3 Troubleshooting Table 3F continued from previous page Troubleshooting Chart Fault Messages Displayed on Water Heater Interface FAULT DESCRIPTION CORRECTIVE ACTION e Vent air intake lengths exceed the maximum allowed lengths Refer to Section 3 General Venting of the Armor Wall Mount Installation and Operation Manual for proper lengths e Check for obstruction or blockage in the vent air The actual fan RPM is 30 lower than what Fan Speed Low intake pipes or at terminations will require a manual is being called for reset once the condition has been corrected Press the RESET button on the SMART SYSTEM display to reset e Check the wiring connections at the fan and at the main control board e Replace the fan e Replace the main control board e Replace fuse F4 on the control board see page 24 of Blown fuse this manual e Vent air intake lengths exceed the maximum allowed lengths Refer to Section 3 General Ven
17. 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 Wall Mount Installation and Operation Manual Inspect water heater interior l Remove the front access cover and inspect the interior of the water heater Vacuum any sediment from inside the water heater and components Remove any obstructions Clean condensate trap l Remove the clean out cap on the bottom of the trap Let the condensate and any debris drain out Fill with fresh water until the water begins to pour out of the drain Replace the clean out cap and resume operation 20 CONDENSATE FROM HEAT EXCHANGER Figure 2 1 Condensate Trap 2 PVC CAP WITH BLOCKED DRAIN SWITCH RETAINING SCREW CONDENSATE DRAIN REMOVABLE CAP TO CLEAN OUT TRAP A WARNING 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 Check all piping for leaks A WARNING Eliminate all system or water heater leaks Leaking water may cause severe property damage Inspect all water and gas piping and verify to be leak free Look for signs of leaking lines and correct any problems found Check gas line using the procedure found in Section 7 Gas Connections of
18. Phone Number On Volts 18 LLI O gt oc Lu v NOTIFICATION 13 1 Service Service Manual Viewable and changeable control parameters Before changing parameters note the CAUTION ae 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 This parameter must be accessed to set the clock The internal clock does not adjust for NOTICE J Daylight Savings Time and therefore will require a manual adjustment The clock is automatically updated whenever a PC is connected and the WinPro Installer program is started 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 Software version is read only 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 the Temperature Units parameter The default is F Domestic Hot Water DHW Night S
19. 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 Check the wiring between the external control and the unit Replace the control Establish a heating load to remove the heat from the tank 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 Wall Mount Installation and Operation Manual for the proper piping methods for the water heater 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 Wall Mount Installation and Operation Manual for water heater pump specifications Service Manual 3 Troubleshooting continued Table 3F continued from previous page Troubleshooting Chart Fault Messages Displayed on Water Heater Interface C Faun DESCRIPTION CORRECTIVE ACTION 120 VAC input to t
20. Service Manual E 37 Notes 38 Notes 39 5 Lochinvar Y High Efficiency Water Heaters Boilers and Pool Heaters 300 Maddox Simpson Parkway Lebanon TN 37090 615 889 8900 Fax 615 547 1000 www Lochinvar com Revision Notes Revision A ECO 011832 initial release WA SER RevA 12 12
21. This set point will be applied to the inlet sensor when a tank sensor is not installed This parameter can be changed by the installer by accessing the DHW Tank Set point parameter The temperature range of this parameter tank minimum set point to tank maximum set point The default value is 125 F 52 C Tank Set Point Offset The tank set point offset measures how far the actual temperature must go above the set point before the call for heat ends the water heater will turn off This parameter can be changed by the installer by accessing the Tank Set Point Offset parameter Tank Set Point Differential The tank temperature must drop this amount below the tank set point DHW Tank Set point parameter before the water heater turns back on The installer can adjust this setting by accessing the Tank Set point Differential parameter The minimum setting is 0 0 C and the maximum is 40 F 22 C The default setting is 6 F 3 C Tank Minimum Set Point This setting controls the minimum tank set point for the tank temperature The installer can adjust this by accessing the Tank Minimum Set point parameter The minimum setting is 60 F 16 C and the maximum setting is the maximum tank set point Tank Maximum Set point parameter The default value is 60 16 C Tank Maximum Set Point This setting controls the maximum tank set point for the tank temperature The installer can adjust this by accessing the Tank Maximum Set po
22. WA SER Rev A WALL MOUNT WATER HEATER Service Manual Models 125 200 EE pmm lt ais majat morte eters Ea A WARNING This manual must only be used by a qualified heating installer service technician Read all instructions including this manual and the Armor Wall Mount 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 High Efficiency Water Heaters Boilers and Pool Heaters Save this manual for future reference Contents CONTENTS ccccccccsssssssessseseessrsessrsesssrssuseuserseesersecaeess 2 2 MAINTENANCE Hazard Definitions asridir kainananan aiaiai 2 Maintenance and Annual Startup seen 19 23 PLEASE READ BEFORE PROCEEDING 0005 3 3 TROUBLESHOOTING Handling Ceramic Fiber Materials ccc ccccceeeeeeeeeees 3 Before Troubleshooting cccscccccssseeccceseeeeceeeeeesseaseees 24 When servicing water heater cccccccccesseeeesseeeeeeees 3 Check Control Module Fuses cccccccsseeeeeeeeeeeeeees 24 Water heater operation cccecceeceeeseseeeereeseseeeees 3 Table 3A Troubleshooting Chart No Display 25 WHAT IS IN THIS MANUAL 0 0 ccccccecececeeteteeeeees 4 Checking Temperature Sensors ececeeseceeseereeereees 26 1 SERVICE Table 3E Troubleshooting Char
23. XIT key Display Timeout This is the time for which the display remains illuminated The range is 10 seconds to 10 minutes The default is 3 minutes Data Logging Reset log errors The reset log errors function clears the last 10 errors log Functions Service Mode Delay 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 any 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 previous state This parameter can only be changed by the installer by accessing the Service Mode Delay parameter The time range of this parameter is 1 to 10 minutes The default value is 10 minutes Freeze Protection Pump On The SMART SYSTEM control will turn on the water heater and system pump outputs whenever the inlet temperature drops below this setting This is done to prevent the water in the heat exchanger from freezing Certain low temperature applications such as snow melt can operate at temperatures around freezing so this setting needs to be lowered in these cases The installer can adjust the temperature at which the pump outputs are turned on by accessing Freeze Protection Pump On parameter The minimum setting is 3 F 19 C and the maxi
24. changer and set aside Remove the heat exchanger access cover burner and gas air arm assembly A WARNING Tbe water heater contains ceramic 11 12 13 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 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 Use a vacuum cleaner to remove any accumulation on the water heater heating surfaces Do not use any solvent Brush the heat exchanger while dry using a nylon bristle brush Caution DO NOT use a metal brush Re vacuum the heat exchanger Finish cleaning using a clean cloth dampened with warm water Rinse out debris with a low pressure water supply 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 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 Perform start up and check out procedures in the Check Flame and Combustion Section 10
25. check the wiring back to the main control board Replace the main control board if necessary The temperature rise across the heat Delta T High exchanger has exceeded the set parameters for the water heater e If 120 VAC is present on a call for heat and the water heater pump is not operating replace the pump e 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 Wall Mount Installation and Operation Manual for water heater pump specifications 33l 3 Troubleshooting Service Manual Table 3F continued from previous page Troubleshooting Chart Fault Messages Displayed on Water Heater Interface FAULT DESCRIPTION CORRECTIVE ACTION Olt ATTEN T ael Outlet water temperature has exceeded the maximum outlet water temperature External control is cycling too often Rem Ctrl Fit Service Blk While the unit is in Service Mode the outlet temperature has exceeded 185 F e Verify that the system is full of water and that all air has been properly purged from the system e Verify that the water heater is piped properly into the system Refer to Section 6 System Piping of the Armor Wall Mount Installation and Operation Manual for the proper piping methods for the water heater 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
26. e enabled one of two ways With the BMS Thermostat Input parameter set to ACTIVE the water heater will be enabled by closing the tank thermostat input When 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 BMS The set point or modulation of the water heater may be controlled through the 0 10V BMS input or through ModBus When the BMS parameter 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 ModBus When BMS is set to ACTIVE see BMS and the water heater is being controlled through ModBus set ModBus parameter 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 ModBus T O This parameter determines 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 readings 16 Service Manual This parameter is adjustable by the installer by accessing the ModBus T O parameter The adjustment range of this parameter is 5 seconds
27. e range of this parameter is the Volts at Minimum value to 10 0V The default value is 10 0V 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 is set by the Rate at Minimum Volts parameter When used with a Cascade this percentage applies to the total output of the Cascade The minimum value is 0 and the maximum is the Rate at Maximum Volts setting The default value is 20 17 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 When used with a Cascade this percentage applies to the total output of the Cascade The minimum value is the Rate at Minimum Volts setting and the maximum is 100 The default value is 100 Set Point at Minimum Volts 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 is set by the Set Point at Maximum Volts parameter The minimum value is 32 F 0 C and the maximum is the Set Point at Maximum Volts setting The default value is 70 F 21 C Set Point at Maximum Volts When programmed
28. e this procedure to access menus from the display panel SCREEN BUTTON STATUS OPERATION DISPLAY 10 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 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 Press the RIGHT SELECT soft key SAVE Rotate the NAVIGATION dial counterclockwise to select a category STANDBY TAHKE EEE HEHO 4SETFOIHT SHDN STANDBY SHUT COMM SHUTDOWN TAHKE EEE E MEHO 4SETFOIHT SHOH SHUTDOWN PASSWORD OOo EsIT HEST SAWE SHUTDOWN PASSWORD 2000 EsIT SHUTDOWN PASSWORD 2300 HEST SAUE EsIT SHUTDOWN PASSWORD 22093 HEST SAUE EsIT SHUTDOWN gt GENERAL DATA LOGGING FUMCT IONS DHL SETTINGS HOME 47 SCROLL HEAT SHWE Service Manual 1 Service continued Display panel parameter access T a T T e T a N Table 1C This is a typical example of accessing a parameter shown for parameter DHW Settings TANK MIN Setpt SCREEN BUTTON STATUS OPERATION DISPLAY This example shows how to access parameter Temperature Settings The first display shown is at the
29. ed may result in minor or moderate injury A CAUTION CAUTION used without the safety alert symbol indicates a potentially hazardous situation which if not CAUTION avoided may result in property damage NOTICE NOTICE indicates special instructions on installation operation or maintenance that are important but not related to personal injury or property damage Please read before proceeding A WARNING Installer Read all instructions including this manual and the Armor Wall Mount Installation and Operation 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 Handling ceramic fiber materials REMOVAL OF COMBUSTION CHAMBER LINING A WARNING The combustion chamber insulation in this appliance contains ceramic fiber material Ceramic fibers can be 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 th
30. elay The louver proving switch air pressure switch and blocked drain switch must close TAHKE D Ea ai mS eS HEHO et SlREEH SHOH PRE PURGE m The control starts the prepurge cycle TAHE WAFS MEHI yI SCEEEH SHOH IGNITION i The control starts the trial for ignition by firing the spark electrode and opening the gas valve THHE WS Feizs 3 MEHU S SCREEMH SHOH PUST PURGE i If flame is not detected after the sparking ends the control will perform a postpurge then start another prepurge cycle and try TAHE 113 F 12593 to light the burner again HEHU S SCREEM SHOH 4246 z If flame is detected it holds the firing rate steady for a few 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 TAHKE 119 Fel253 a 0 10V BMS signal E MEHU oa ScCREEHM SHOH Once the call for heat is satisfied the control will turn off the burner The blower will continue to run during the postpurge TAHKE 129 a period HEHU a SCEEEH SHOH BLOCKED The water heater pump will continue to run for its respective pump delay time before turning off A 60 second anti cycle period sale A Prizes 3 will start which will delay any new call for heat until it times out MEHU st SCREEH SHEH STANDBY In Standby ready to start a new cycle TAHE 128 F C1253 MEHO SETPOIHT SHOH 1 Service Display panel menu access Service Manual Table 1B Us
31. eplace 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 Sla S1b outlet sensor and S3a S3b flue sensor Please reference the wiring diagram in the Armor Wall Mount Installation and Operation Manual for correct terminal location Table 3B Inlet System Sensor Resistance vs Temperature a ee ee 194 SE O a T O E E Table 3C Outlet Water Sensor Resistance vs Temperature Temperature Resistance Temperature Resistance 68 eo 17 146 f 6 2500 17 2492 o 8 8406 f 94 A aosa 8 S 6090 19 s6 E eto o nomo 2736 Y T w sws o Table 3D Flue Sensor Resistance vs Temperature O 50 258500 158 16 870 125 500 176 12000 Oo 6 80220 19 8674 590 212 6369 50 158 176 194 212 35 270 24160 Sas p86 ee as 26 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 14 inches w c LP gas pressures should be between 8 inches w c and 14 inches w c e Refer to Section 7 Gas Connections of the Armor Wall Mount Installation and Operation Manual for detailed information concerning the gas supply e Refer to the Gas Valve Adjustment Procedure on page 37 of this manual for the proper gas valve setting
32. er relief valve 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 Wall Mount Installation and Operation Manual before proceeding further Service Manual Safety relief valves should be re inspected a Ws 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 Following installation the valve lever must A WARNING 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
33. erous operation Always disconnect power to the water heater before servicing Failure to comply could result in severe personal injury death or substantial property damage A WARNING 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 Before troubleshooting Have the following items a Voltmeter that can check 120 VAC 24 VAC and 12 VDC b Continuity checker c Contact thermometer Check for 120 VAC minimum 102 VAC to maximum 132 VAC to water heater 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 Make sure all external limit controls are installed and operating Check the following l Wire connectors to control module are securely plugged in at the module and originating control Gas pressures e Maximum 14 inches w c natural and LP with no flow lockup or with water heater on e Minimum 4 inches w c natural 8 inches w c LP with gas flowing verify during water heater startup 24 Service Manual Check control module fuses NOTICE 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 operatin
34. etback Offset Once the unit s internal clock has been set correctly the Night Setback feature can be used to program a lower set point during unoccupied times When in night setback the control reduces the set point by a fixed amount For DHW it subtracts the DHW night setback offset from the tank set point Tank Set point parameter NOTE The DHW night setback will not work without a tank sensor installed The installer may adjust the DHW night setback offset by accessing the DHW Night Setback Offset parameter The minimum setting is 0 F 0 C and the maximum setting is 90 F 50 C 14 Domestic Hot Water DHW Night Setback On Times This is the time at which the Night Setback Offset becomes active There are 7 start times and 7 stop times each for the DHW night setback feature The DHW Night Setback On Times 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 Note that the DHW recirculation pump will stop when night setback starts and start when night setback stops The installer may adjust the DHW start triggers in the DHW Night Setback On Times parameter This screen shows the start trigger number the day of the week and the time of day NOTICE Please note that the brackets denote screen status 1 When t
35. eter The time range for this parameter is 0 months to 100 months The default time is 0 months 18 Service Manual This feature has been disabled by the manufacturer To enable this feature change the Service Notification in Months parameter to the desired time range Service Notification Running Time 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 the Service Notification Running Time parameter The time range for this parameter is 0 hours to 17 500 hours The default time is 8 760 hours Service Notification Cycles 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 the Service Notification Cycles parameter The range for this parameter is 0 cycles to 100 000 cycles The default is 50 000 cycles Reset Maintenance Reminder Once service has been completed the service notification counter should be reset This parameter can be reset by the installer by accessing the Reset Maintenance Reminder parameter Once accessed press the R
36. ff device by turning the manual shutoff valve to the a re er O pe ein oe paon o OFF position and ensuring that the water heater shuts down a O E A ee and registers an alarm Open the manual shutoff valve paper clip into the hole and press the button once and hold rS ea ee een ooe for 5 seconds to place the water heater into Service Mode l In Service Mode the water heater will fire at ignition speed 7 Turn the main power off to the water heater and replace the and will then modulate up to full fire flue temperature sensor into the flue pipe connection 4 Insert the probe from a combustion analyzer into the hole g Place the water heater back into normal operation left by the removal of the flue temperature sensor A WARNING You must replace the flue gas temperature sensor to prevent flue gas spillage into the room Failure to comply could result in severe personal injury death or substantial property damage 5 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 CORRECTIVE ACTION e Refer to Section 3 General Venting of the Armor Wall Mount Installation and Operation Manual for the proper ven
37. g 1 Turn OFF power to the water heater at the external line switch 2 Remove top access cover 3 Remove the control module cover 4 Inspect fuses F1 F2 and F3 see FIG 3 1 below Figure 3 1 Control Module Fuses F3 80 AMP FUSE 24V DC POWER SUPPLY F1 5 AMP FUSE PUMPS F2 3 15 AMP FUSE BLOWER 5 The water heater is shipped with three 3 spare fuses in a plastic bag attached to the control module cover 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 A WARNING Do not jumper fuse or replace with any fuse except as specified Failure to comply could result in severe personal injury death or substantial property damage 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 Wall Mount Installation and Operation Manual after completing water heater service Service Manual 3 Troubleshooting continueg Table 3A Troubleshooting Chart No Display FAULT CAUSE CORRECTIVE ACTION e Check external line switch fuse or breaker e Check position of ON OFF switch Turn switch to the ON position No 120 VAC supplied to unit e Check 120 VAC through the ON OFF switch e Check wiring harness connection between display board
38. he main control board has e Check 120 VAC supply to the transformer dropped below 80 VAC e Check wiring connections at the low voltage terminal Strip Low 24 VAC e Check the wire size length to remote devices e Replace the transformer The main control board has detected VEDIT E iela internal fault e Turn the 120V power OFF and ON e Replace the main control board The main control board has detected e Turn the 120V power OFF and ON Write EEProm internal fault e Replace the main control board The main control board has detected Turn the 120V power OFF and ON ol LR uae internal fault Replace the main control board The main control board has detected Turn the 120V power OFF and ON No Error Stored internal fault Replace the main control board Restore the default parameters Fatal Error The main control board has detected j in control l Parameters internal fault Replace the main control board Replace the display board 3 Troubleshooting Combustion Analysis Procedure Service Manual Table 3G Flue Products 1 Remove the flue temperature sensor from the flue pipe NaturalGas Propane connection Note Combustion measurements will be made 2 If the water heater is OFF place the water heater into the 8 0 10 3 0 6 5 90 11 4 1 6 9 active position by pressing the RIGHT SELECT ON key see page 5 6 Once the combustion analysis is complete test the safety shuto
39. he 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 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 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 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 General menu or press the LEFT SELECT EXIT key to return to the General menu without saving the changes Domestic Hot Water DHW Night Setback Off Times The stop triggers for the DHW night setback feature can be adjusted by accessing DHW Night Setback Off Times parameter The stop triggers are programmed the same way as the start triggers 1 Service continued To save any changes and return to the Home Screen press the RIGHT SELECT HOME key To return to the Status Screen without saving the changes press the LEFT SELECT E
40. int parameter The minimum setting is the minimum tank set point Tank Minimum Set point parameter and the maximum setting is 190 F 88 C The default value is 140 F 60 C 15 1 Service Anti Cycling Anti Cycling Time Once a DHW demand has been satisfied a set amount of time must elapse before the control will respond to a new DHW 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 the Anti Cycling Override Differential parameter This parameter can be changed by the installer by accessing the Anti Cycling Time parameter The time range for this parameter is 1 minute to 10 minutes The default value is 1 minute Anti Cycling Override Differential The control will bypass the anti cycling time if the inlet water temperature drops too much The control will use the inlet water temperature at the time it shut off as the starting point If the inlet temperature drops below the temperature parameter the control will abort anti cycling and allow the water heater to fire This parameter can be changed by the installer by accessing the Anti Cycling Override Differential parameter The temperature range of this parameter is 0 F 0 C to 54 F 30 C The default value is 10 F 6 C Control modes BMS Thermostat Input When controlling the water heater through the 0 10V BMS input or through ModBus the water heater can b
41. is appliance to cristobalite 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 WE Avoid breathing dust and contact with skin and eyes e Use NIOSH certified dust respirator N95 This type of respirator is based on the OSHA requirements for cristobalite at the time this 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 e Wear long sleeved loose fitting clothing gloves and eye protection M Apply enough water to the combustion chamber lining to prevent airborne dust Mi Remove the combustion chamber lining from the water heater and place it in a plastic bag for disposal W Wash potentially contaminated clothes separately from other clothing Rinse clothes washer thoroughly NIOSH stated First Aid WE Eye Irrigate immediately M Breathing Fresh air NOTICE Service Manual When calling or writing about the water heater Please have the water heater model and serial number from the water heater rating plate Consider piping and installation when determining water heater location see the Armor Wall Mount Installation and Operation Man
42. isplay l to reset e Replace the sensor if necessary e Measure the resistance of the sensors and compare the resistance to the tables on page 26 of this manual Louver Proving e Check function of remote devices will require a manual CCA ANGO An optional remote proving switch is not ERO ARN Making the RESET button on the SMART SYSTEM display to reset e Check for loose or misplaced jumper if louver proving switch is not installed e Inspect the heat exchanger Reference page 23 of this manual for the procedure on how to clean the flue side of the heat exchanger e 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 JUE A ael The stack temperature has exceeded the set parameters for the water heater e Verify that the vent air intake pipes are properly installed and that there are no obstructions e Replace the main control board Scaling has reduced water flow e Deliming may be required e Verify that the system is full of water and that all air has been properly purged from the system e Verify that the water heater is piped properly into the system Refer to Section 6 System Piping of the Armor Wall Mount Installation and Operation Manual for the proper piping methods for the water heater e Check for 120 VAC to the water heater pump motor on a call for heat If voltage is not present
43. let 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 If any of the water heater outlet temperatures reach the maximum cascade set point the water heater will then modulate down on its own in order to keep its outlet temperature within the maximum cascade 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 the Maximum Cascade Set Point parameter The temperature range of this parameter is 32 0 C to 190 F 88 C The default maximum cascade set point is 185 F 85 C Minimum On Off Time In order to prevent units in a Cascade from short cycling this parameter defines the minimum ON and OFF time for each unit This timer is overridden when the call for heat ends The installer can adjust this time by accessing the Minimum On Off Time parameter The minimum setting is 0 seconds and the maximum setting is 10 minutes The default is 30 seconds 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 the Minimum Next On Time parameter The minimum setting is 0 minutes and the maximum setting is 10 minutes The defau
44. lt is 60 seconds Boiler Size When water heaters of different sizes are connected together in a Cascade the Leader water heater has to know the size of each water heater in that Cascade The Boiler Size parameters allow the installer to program the size based on the Cascade address This screen shows the Cascade address and the size of the water heater with that address in BTU hr 1 When the Boiler Size screen is first accessed Cascade Address 0 Leader is shown 2 Press the NAVIGATION dial to access the first digit of the water heater size Rotate the NAVIGATION dial to adjust the first digit To access the next digit press the NAVIGATION dial again Continue this process until the correct water heater size to the nearest 1000 BTU hr is shown Press the RIGHT SELECT SAVE key 3 Rotate the NAVIGATION dial to select the address of the next water heater in the Cascade Repeat Step 2 4 Once the size of the last water heater in the Cascade has been entered and saved press the LEFT SELECT EXIT key to return to the Control Modes menu 5 Ifno other parameters are to be adjusted press the RIGHT SELECT HOME key to save the new settings and return to the Status screens The SMART SYSTEM control automatically uses the Efficiency Optimization Cascade type when controlling water heaters of different sizes Service Manual Circulation pumps DHW Pump Delay The DHW pump delay parameter sets the length of time the DHW
45. mum setting is 45 F 7 2 C The default setting is 45 F 7 2 C NOTICE Freeze Protection Burner On If running the pumps does not prevent the inlet temperature from falling closer to freezing the SMART SYSTEM control will fire the burner at low fire The installer can adjust the temperature at which the burner fires by adjusting the Freeze Protection Burner On parameter The minimum setting is 3 F 19 C and the maximum setting is 45 F 7 2 C The default setting is 37 F 2 8 C Never put the Freeze Protection Pump on a setting lower than the Freeze Protection Burner On setting Service Manual Freeze Protection Burner Differential Once the burner has started firing due to a low inlet temperature the inlet temperature must increase by this amount before the burner turns back off The installer can adjust this differential by accessing the Freeze Protection Burner Differential parameter The minimum setting is 0 F and the maximum is 20 F The default setting is 5 F 2 8 C DHW Settings DHW Tank Set Point By installing a tank sensor the SMART SYSTEM control can perform the tank thermostat function The SMART SYSTEM control automatically detects the presence of this sensor and generates a DHW call for heat when the tank temperature drops below the tank set point differential Tank Set point Differential parameter and finishes the call for heat when the tank temperature reaches tank set point offset
46. ntenance see the following pages for instructions General e Address reported problems e Inspect interior clean and vacuum if necessary e Check water heater area e Check pressure temperature e Clean condensate trap and fill with fresh gauge water e Check for leaks water gas flue condensate e Verify flue and air lines in good condition and sealed tight e Check system water pressure system piping expansion tank e Check vent piping e Check control settings Check air piping e Check ignition and flame sense electrodes Poe sand a any deposits clean and Monthly e Check air and vent termination reposition screens ANNUAL START UP e Check wiring and connections e Check relief valve e Perform start up checkout and e Check condensate drain system performance verification per Section 10 in the Armor Installation and Operation e Check air vents Manual eCheck Delta T Temperature e Flame inspection stable uniform Rise e Flame signal at least 10 microamps at high fire e Clean the heat exchanger if flue temperature is more than 54 F above Every return water temperature 6 months e Check water heater piping gas e Check Delta T Temperature Rise and water for leaks If combustion or performance ae e Operate relief valve indicate need e Clean heat exchanger e Remove and clean burner using compressed air only e Clean the blower wheel 2 Maintenance A WARNING A WARNING
47. ntrol board e Verify that the system is full of water and that all air has been properly purged from the system e Verify that the water heater is piped properly Refer to Section 6 System Piping of the Armor Wall Mount Installation and Operation Manual for the proper piping methods for the Armor water heater e Check 120 vac to water heater pump motor on a call for heat If voltage is not present check wiring back The outlet water temperature has exceeded to the main control board Auto Reset 7 aa ae High Limit the setting of the automatic reset high limit Replace the main control board if necessary e If 120 vac is present on a call for heat and the water heater pump is not operating replace the pump e If the manual reset high limit has tripped check setting of the device e Check resistance of water sensors and compare to Table 3B on page 26 of this manual Replace sensor if necessary e Verify that the system is full of water and that all air has been properly purged from the system e Verify that the water heater is piped properly Refer to Section 6 System Piping of the Armor Wall Mount Installation and Operation Manual for the proper Manual Reset piping methods for the water heater High Limit will require a manual TCA G The outlet water temperature has exceeded ESR RE the fixed setting of the manual reset high the RESET button on the limit e Replace the main control board if necessary SMART SYSTE
48. rrected Press the RESET button on the SMART SYSTEM display to reset e Verify system is full of water and all air has been purged from the system e Check for loose or misplaced jumpers if flow switch is not installed e Replace fuse F2 on the control board see page 24 of Blown fuse this manual e 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 e Inspect condensate trap for blockage Clean if The blocked drain switch has detected necessary excessive condensate build up inside the unit e Check for loose wiring connection at wire harness plug e Bad blocked drain switch Replace switch APS e Check the wiring connections to switch Wires should be connected to the common and normally closed terminals e Air intake lengths exceed the maximum allowed lengths Refer to Section 3 General Venting of the Armor Wall Mount Installation and Operation Manual for proper lengths e Check for obstruction or blockage in the air intake pipes or at terminations e Check reference hoses connected to the air pressure switch for blockage or obstruction e Inspect the burner Reference page 22 of this manual for removal and cleaning procedures Replace if necessary e Inspect the heat exchanger Reference page 23 of this manual for remo
49. stallation 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 l installed and that there are no obstructions Flame Fail Ign will require a manual Check for 24 VAC to the gas valve at the 2 pin reset once the condition connection on the side of the main control board during has been corrected the ignition attempt If no voltage is present replace Press the RESET button the main control board 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 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 e Replace the main control board J 29 PE Service
50. t Noisy System 27 The Armor Wall Mount Display c ccccccescceseeeeeeeeeeeee 5 Table 3F Troubleshooting Chart Fault Messages 28 35 Control NOUS eee ee ene ee 6 Combustion Analysis Procedure eee ein 36 Control OUtQUtS cee ecseecescescesceeesessesseeeseeeentaneeeeees 7 Table sG FIM PrOGUClS sssusa 36 General Operator so iicsicccsiienapsicsaseticesisnsnsaicnsnsestvesuiteseamatads 8 Table 3H Troubleshooting Chart Combustion Levels 36 Sequence of Operation ccceceeeececessesesessessessesereereees 9 Gas Valve Adjustment Procedure ieee 37 Display Panel Menu ACCESS ccccceeceeeeeeeeseeeeseeeeeees 10 Revision Notes tecstevecssetsvocenadnecasatetenetatevaenieeentte Back Cover Display Panel Parameter ACCESS 0 ceeeeeeeeeeeeeeeeees 11 Parameter T ADCs o ccsincndccincerccvcsunehadeceddeenadccnadeleucindecuaes 12 13 Viewable and Changeable Control Parameters 14 18 Hazard definitions The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product A DANGER a indicates an imminently hazardous situation which if not avoided will result in death or serious A WARNING a indicates a potentially hazardous situation which if not avoided could result in death or serious CAUTION indicates a potentially hazardous situation which if not avoid
51. t 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 NOTICE Please note that the brackets denote screen status 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 Service Manual Service Manual 1 Service continued Table 1A Sequence of operation OPERATION DISPLAY START h The control will turn on the water heater pump always ON except in Night Setback The flow switch and or LWCO must close TAHE 11S F eles MEHU et SCREEH SHOH The control turns on power to the louver r
52. t water heater to 40 thus eliminating the sudden drop in total output of the Cascade 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 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 Efficiency optimization is automatically selected when heaters of different sizes are programmed into the Leader water heataer see Boiler Size on page 17 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 out
53. the display should be at least 10 microamps 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 See Section 3 Troubleshooting in this manual for other procedures to deal with low flame signal Review with owner l Emphasize the need to perform the maintenance schedule specified in this manual Remind the owner of the need to call a licensed contractor should the water heater or system exhibit any unusual behavior Remind the owner to follow the proper shutdown procedure and to schedule an annual start up at the beginning of the next heating season 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 l Shut down water heater e Follow the To Turn Off Gas to Appliance instructions for the water heater in Section 10 Startup of the Installation and Operation Manual e Do not drain the water heater unless it will be exposed to freezing temperatures If using freeze prevention fluid in system do not drain Allow time for the water heater to cool to room temperature if it has been firing Remove the nuts securing the heat exchanger access cover to the heat ex
54. ting and air intake methods for the water heater POSSIBLE CAUSE Vent Air Intake Length or Obstruction Check for obstructions at the vent air intake terminals Refer to Section 7 Gas Connections of the Armor Wall Mount Installation and Operation Manual for the proper gas supply for the water heater Gas Supply Pressure Refer to page 22 of this manual for burner removal and cleaning procedures Dirty Damaged Burner Replace burner if necessary er CA EUEN A uag Refer to page 37 of this manual for the gas valve adjustment procedure 36 3 Troubleshooting continueg Gas valve adjustment procedure If adjustment of the gas valve is deemed necessary use the following procedure 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 counterclockwise to increase CO levels or a 1 4 turn clockwise to decrease CO 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 2 Gas Valve Adjustment THROTTLE ADJUSTMENT SCREW In v IC IR
55. ting of the Armor Wall Mount Installation and Operation Manual for proper lengths Fan High OR Fan Speed High CS EE ouA The actual fan RPM is 30 higher than what reset once the condition is being called for has been corrected Press the RESET button on the SMART SYSTEM display to reset e Check for obstruction or blockage in the vent air intake pipes or at terminations e Check the wiring connections at the fan and at the main control board e Replace the fan e Replace the main control board e Check the sensors and their associated wiring Repair or replace the sensor or wiring if damaged Sensor Open will require a manual STATO Either the inlet water or outlet water WE st east temperature sensor has been disconnected the RESET button on the e Measure the resistance of the sensors and compare the resistance to the tables on page 26 of this manual SMART SYSTEM display to reset e Replace the sensor if necessary 32 rai Service Manual 3 Troubleshooting continueg Table 3F continued from previous page Troubleshooting Chart Fault Messages Displayed on Water Heater Interface FAULT DESCRIPTION CORRECTIVE ACTION Sensor Shorted e Check the sensors and their associated wiring will require a manual Repair or replace the sensor or wiring if damaged GCA ANGO Either the inlet water or outlet water EAV REJ temperature sensor has been shorted the RESET button on the SMART SYSTEM d
56. tinuity 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 l Start water heater and perform checks and tests specified in Section 10 Start up of the Armor Wall Mount Installation and Operation Manual 2 Verify cold fill pressure is correct and that operating pressure does not go too high 22 Service Manual Check burner flame l Inspect flame through observation window 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 Remove the burner reference FIG 2 2 below When replacing the burner ensure gasket is in good condition and positioned correctly FIG 2 2 Figure 2 2 Burner Assembly HEAT EXCHANGER DOOR NUTS o QTY 6 A SCREWS QTY 5 IMG00549 AIR GAS ARM Check flame signal l At high fire the flame signal shown on
57. to 2 minutes The default value is 10 seconds Cascade Address 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 The tank sensor must be connected to the Leader water heater The default address is 1 Cascade Type There are two 2 options for the way a Cascade divides the load between its heaters The first is Lead Lag designated as L Lin the menu This method is used when it is desired to have the least amount of total flow through the water heaters This method will modulate the last two 2 water heaters This provides for smooth transitions when a water heater turns on or off 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 thus eliminating the sudden jump in total output of the Cascade 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 las
58. ual Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee When servicing water heater e To avoid electric shock disconnect electrical supply before performing maintenance e To avoid severe burns allow the water heater to cool before performing maintenance Water heater operation e Do not block flow of combustion or ventilation air to the water heater e Should overheating occur or gas supply fail to shut off do not turn off or disconnect electrical supply to circulator Instead shut off the gas supply at a location external to the appliance e Do not use this water heater if any part has been under water The possible damage to a flooded appliance can be extensive and present numerous safety hazards Any appliance that has been under water must be replaced What is in this manual Service The Armor wall mount display Display panel readout buttons and their functions Control module inputs e Control module inputs and options Control module outputs e Control module outputs and options General e How the water heater operates e How the control module operates e Access modes user and installer e Sequence of operation Water Heating Control panel menu access e Accessing programming mode and locating menus See separate guide covering the PC interface Control panel parameter access e Accessing and changing parameters
59. val and cleaning procedures Replace if necessary e Faulty air pressure switch Replace switch APS HEX Temp Sw Open QuilBvccpicaewerieried Either the air pressure switch contacts are Recametecnitarcentetstesm open or the O temp heat exchanger switch EaR n R Nas opened the RESET button on the SMART SYSTEM display to reset LER 28 eal Service Manual 3 Troubleshooting continueg 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 e The control board will release the call for heat after a Anti cycling for heat too quickly after the previous call for set time period heat has ended The control board will release the call for heat if the outlet temperature drops too quickly Check wiring harness connection at the gas valve and The unit has failed to prove main burner tthe main control board ignition after four 4 attempts Inspect spark electrode and associated wiring for damage and connection Reference page 22 of this manual for removal and cleaning procedures Replace if necessary 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 Wall Mount In

Armor Wall Mount Service Manual

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