Lochinvar ARMOR 151 - 801 User manual

Service Manual
Models: 151 - 801
This manual must only be used by a
qualified heating installer / service
technician. Read all instructions,
including this manual and the Armor
Water Heater Installation and
Operation Manual, before installing.
Perform steps in the order given.
Failure to comply could result in severe
personal injury, death, or substantial
property damage.
WARNING
Save this manual for future reference.
AWII-SER Rev A

2
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.
DANGER
WARNING
CAUTION
CAUTION
NOTICE
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious
injury.
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious
injury.
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate
injury.
CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not
avoided, may result in property damage.
NOTICE indicates special instructions on installation, operation, or maintenance that are important but not
related to personal injury or property damage.
CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Hazard Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
PLEASE READ BEFORE PROCEEDING . . . . . . . . . . . . 3
Handling Ceramic Fiber Materials . . . . . . . . . . . . . . . . . . . 3
When servicing water heater . . . . . . . . . . . . . . . . . . . . 3
Water heater operation . . . . . . . . . . . . . . . . . . . . . . . . 3
WHAT IS IN THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . 4
1. SERVICE
The Armor Water Heater Display . . . . . . . . . . . . . . . . . . . . 5
Control Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Control Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
General Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Display Panel Menu Access . . . . . . . . . . . . . . . . . . . . . . 10
Display Panel Parameter Access . . . . . . . . . . . . . . . . . . . 11
Parameter Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-13
Viewable and Changeable Control Parameters . . . . . . . 14-18
2. MAINTENANCE
Maintenance and Annual Startup . . . . . . . . . . . . . . . . . . 19-23
3. TROUBLESHOOTING
Before Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Check Control Module Fuses . . . . . . . . . . . . . . . . . . . . . 24
Table 3A - Troubleshooting Chart - No Display . . . . . . . . 25
Checking Temperature Sensors . . . . . . . . . . . . . . . . . . . 26
Table 3E - Troubleshooting Chart - Noisy System . . . . . 27
Table 3F - Troubleshooting Chart - Fault Messages . . . . 28-35
Combustion Analysis Procedure . . . . . . . . . . . . . . . . . . . 36
Table 3G - Flue Products . . . . . . . . . . . . . . . . . . . . . . . . . 36
Table 3H - Troubleshooting Chart - Combustion Levels . 36
Gas Valve Adjustment Procedure . . . . . . . . . . . . . . . . . . 37-38
Revision Notes . . . . . . . . . . . . . . . . . . . . . . . . . Back Cover
Contents

Service Manual
Please read before proceeding
Installer – Read all instructions,
including this manual and the Armor
Water Heater 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.
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 Water Heater Installation and Operation
Manual).
Any claims for damage or shortage in shipment
must be filed immediately against the
transportation company by the consignee.
3
Handling ceramic fiber materials
REMOVAL OF COMBUSTION CHAMBER LINING
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 this 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.
¢Avoid breathing dust and contact with skin
and eyes.
• 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.
• Wear long-sleeved, loose fitting clothing, gloves,
and eye protection.
¢Apply enough water to the combustion chamber
lining to prevent airborne dust.
¢Remove the combustion chamber lining from the
water heater and place it in a plastic bag for disposal.
¢Wash potentially contaminated clothes separately
from other clothing. Rinse clothes washer
thoroughly.
NIOSH stated First Aid.
¢Eye: Irrigate immediately.
¢Breathing: Fresh air.
WARNING NOTICE
WARNING
When servicing water heater –
• To avoid electric shock, disconnect
electrical supply before performing
maintenance.
• To avoid severe burns, allow the water
heater to cool before performing
maintenance.
Water heater operation –
• Do not block flow of combustion or
ventilation air to the water heater.
• 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.
• 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.

4
Service Manual
What is in this manual?
Service
The Armor water heater display
• Display panel readout, buttons and their functions
Control module inputs
• Control module inputs and options
Control module outputs
• Control module outputs and options
General
• How the water heater operates
• How the control module operates
• Access modes -- user and installer
• Sequence of operation -- Water Heating
Control panel menu access
•Accessing programming mode and locating menus
(See separate guide covering the PC interface.)
Control panel parameter access
• Accessing and changing parameters from the display panel
Quick start information -- parameter table
• An index of available adjustments and readouts, where to
access them and where to find detailed information.
Armor water heater operation
• A: General
• B: Data Logging
• C: Functions
• D: DHW Settings
• E: Anti-Cycling
• F: Control Modes
• G: Circulation Pumps
• H: BMS
• I: Service Notification
Maintenance
• Service and maintenance schedules
• Address reported problems
• Inspect water heater area and water heater interior
• Clean condensate trap
• Check all piping for leaks
• Check air openings
• Flue vent system and air piping
• Check water system
• Check water heater relief valve
• Inspect ignition electrode
• Check ignition ground wiring
• Check all water heater wiring
• Check control settings
• Perform start-up and checks
• Check burner flame
• Check flame signal
• Check flue gas temperature
• General maintenance
• Review with owner
• Cleaning the water heater heat exchanger
• Oiled bearing circulators
Troubleshooting
• Troubleshooting table - No display
• Checking temperature sensors
• Sensor tables
• Troubleshooting table - Fault messages displayed on the
water heater interface
• Combustion analysis procedure
• Gas valve adjustment procedure

1 Service
Service Manual
5
NAVIGATION DIAL
(PRESS OR TURN)
RIGHT SELECT KEY
(SOFT KEY)
LEFT SELECT KEY
(SOFT KEY)
RESET KEY
The Armor water heater display
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

1 Service
6
Service Manual
GAS PRESSURE SWITCH
DHW THERMOSTAT
FLOW SWITCH
TANK SENSOR
SEQUENCER / BUILDING
MANAGEMENT SYSTEM
LOW VOLTAGE
CONNECTION
BOARD
INLET TEMPERATURE
SENSOR
OUTLET TEMPERATURE
SENSOR
FLUE GAS SENSOR
LOUVER PROVING SWITCH
FLAME SENSOR
LOW WATER CUTOFF
BLOCKED DRAIN SWITCH
DISPLAY PANEL
PC INTERFACE
SMART SYSTEM
CONTROL BOARD
AIR PRESSURE SWITCH
Control inputs

Service Manual
7
LOW VOLTAGE
CONNECTION
BOARD
SMART SYSTEM
CONTROL BOARD
ALARM BELL
LOUVER RELAY
RUN TIME CONTACTS
SEQUENCER / BUILDING
MANAGEMENT SYSTEM
WATER HEATER PUMP
IGNITOR
BLOWER
GAS VALVE
DISPLAY PANEL
PC INTERFACE
BUILDING RECIRCULATION
PUMP
Control outputs
1 Service (continued)

1 Service
8
Service Manual
General Operation
How the water heater operates
The Armor water heater uses an advanced stainless steel heat
exchanger and an electronic control module that allows fully
condensing operation. The blower pulls in gas and air and
pushes flue products out of the water heater through the heat
exchanger and flue piping. The control module regulates blower
speed to control water heater firing rate. The gas valve senses the
amount of air flowing into the water heater and 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)
Please note that the brackets ([]) denote
screen status.
NOTICE
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
9
Table 1A Sequence of operation
1 Service (continued)
OPERATION DISPLAY
1. The control will turn on the water heater pump (always ON except
in Night Setback). The flow switch and/or LWCO must close.
2. The control turns on power to the louver relay. The louver
proving switch, air pressure switch, and blocked drain switch
must close.
3. The control starts a 15 second prepurge cycle.
4. The control starts a 4 second trial for ignition by firing the spark
electrode and opening the gas valve.
5. If flame is not detected within 1 second after the sparking ends,
the control will perform a 10 second post-purge, then start
another prepurge cycle and try to light the burner again. On the
501 and larger models, the control will lock out if this second
attempt also fails. On the 400 and smaller models, the control
will perform a total of 4 attempts before locking out.
6. If flame is detected, it holds the firing rate steady for 5 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 a 0-10V
BMS signal).
7. Once the call for heat is satisfied, the control will turn off the
burner. The blower will continue to run during a 10 second
postpurge.
8. The water heater pump will continue to run for its respective
pump delay time before turning off. A 60 second anti-cycle period
will start, which will delay any new call for heat until it times out.
9. In Standby, ready to start a new cycle.

1 Service
10
Service Manual
Display panel menu access
Table 1B Use this procedure to access menus from the display panel
BUTTON SCREEN
STATUS OPERATION DISPLAY
[SHDN] Press the RIGHT SELECT soft key [SHDN].
[YES] Press the LEFT SELECT soft key [YES].
[MENU] 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.
[SAVE] Press the RIGHT SELECT soft key [SAVE].
Rotate the NAVIGATION dial counterclockwise to
select a category.

Service Manual
11
Display panel parameter access
Table 1C This is a typical example of accessing a parameter, shown for parameter DHW Settings, TANK MIN Setpt
1 Service (continued)
BUTTON SCREEN
STATUS OPERATION DISPLAY
This example shows how to access parameter Temperature Settings. The first display shown is at the beginning
of the menu listings, after entering the installer access code.
Rotate the NAVIGATION dial counterclockwise until
the arrow (>) is next to DHW SETTINGS.
Press the NAVIGATION dial one time.
Rotate the NAVIGATION dial counterclockwise until
the arrow (>) is next to TANK MIN SETPT.
Press the NAVIGATION dial one time.
Rotate the NAVIGATION dial to the desired
temperature.
[SAVE] Press the RIGHT SELECT soft key [SAVE] one time.
[EXIT] Press the LEFT SELECT soft key [EXIT] if all desired
changes have been made.
[HOME] Press the LEFT SELECT soft key [HOME].

1 Service
12
Service Manual
Parameter table
Table 1D This table lists SMART SYSTEM control module parameters and where to access them
Menu Sub
Item Description See Page
User Access Installer Access
Display Modify Display Modify
A
1Date and Time 14 Yes Yes Yes Yes
2Software Version (read only) 14 No No Yes No
3Temperature Units (ºC/ºF) 14 Yes Yes Yes Yes
4DHW Night Setback Offset 14 No No Yes Yes
5DHW Night Setback On Times 14 No No Yes Yes
6DHW Night Setback Off Times 14 No No Yes Yes
7Display Timeout 14 No No Yes Yes
B1Reset Last 10 Errors 15 No No Yes Yes
C1Service Mode Delay 15 No No Yes Yes
D
1Tank Set Point 15 Yes Yes Yes Yes
2Tank Set Point Offset 15 Yes Yes Yes Yes
3Tank Set Point Differential 15 No No Yes Yes
4Tank Minimum Set Point 15 No No Yes Yes
5Tank Maximum Set Point 15 No No Yes Yes
E
1Anti-Cycling Time 15 No No Yes Yes
2Anti-Cycling Override Differential 15 No No Yes Yes
GENERAL
DATA
LOGGING
FUNCTIONS
DHW SETTINGS
ANTI-
CYCLING

1 Service (continued)
Service Manual
Menu Sub
Item Description See Page
User Access Installer Access
Display Modify Display Modify
F
1BMS Tstat Input (Active/Inactive) 16 No No Yes Yes
2BMS (Active/Inactive) 16 No No Yes Yes
3ModBus (Active/Inactive) 16 No No Yes Yes
4ModBus T/O (Timeout) 16 No No Yes Yes
5Cascade Address 16 No No Yes Yes
6Cascade Type (L/L / EFF) 16 No No Yes Yes
7Max Cascade Outlet Set Point 17 No No Yes Yes
8Min On/Off Time 17 No No Yes Yes
9Min Next On Time 17 No No Yes Yes
10 Boiler Size 17 No No Yes Yes
G
1DHW Pump Delay 17 No No Yes Yes
2DHW Pump Anti-Seize Delay 17 No No Yes Yes
H
1BMS Type (Power / Set Point) 18 No No Yes Yes
2Volts at Min 18 No No Yes Yes
3Volts at Max 18 No No Yes Yes
4Rate at Min Volts 18 No No Yes Yes
5Rate at Max Volts 18 No No Yes Yes
6Set Point at Min Volts 18 No No Yes Yes
7Set Point at Max Volts 18 No No Yes Yes
8On Volts 18 No No Yes Yes
9Off Differential Volts 18 No No Yes Yes
I
1Service Notification Months 18 No No Yes Yes
2Service Notification Running Time 18 No No Yes Yes
3Service Notification Cycles 19 No No Yes Yes
4Reset Maintenance Reminder 19 No No Yes Yes
5Installer Name and Phone Number 19 No No Yes Yes
CONTROL MODES
CIRCULATION
PUMPS
13
SERVICE
BMS
NOTIFICATION
Parameter table
Table 1D (continued from previous page) This table lists SMART SYSTEM control module parameters and where
to access them

1 Service
14
Service Manual
Viewable and changeable control parameters
CAUTION Before changing parameters, note the
settings so that the unit can be returned to
its original operating parameters.
A: General
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 water heater is first
installed or anytime the water heater has been powered off for
more than four (4) hours. To set the clock, parameter A1
must be accessed.
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 parameter A3. The default is °F.
Domestic Hot Water (DHW) Night Setback Offset
The unit’s internal clock can be set up to run at a lower set
point temperature during unoccupied times. When in night
setback, the control reduces the set point by a fixed amount.
It subtracts the DHW night setback offset from the tank set
point (parameter E2).
NOTE: The DHW night setback will not work without a tank
sensor installed.
The installer may adjust the DHW night setback offset by
accessing parameter A4. The minimum setting is 0°F (0°C)
and the maximum setting is 90°F (50°C).
Domestic Hot Water (DHW) Night Setback On
Times
This is the time at which the DHW Night Setback Offset
becomes active. There are 7 start times and 7 stop times.
Both 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. The installer may adjust the DHW
start triggers in parameter A5. This screen shows the start
trigger number, the day of the week, and the time of day.
1. When the 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 Amenu, or press the LEFT
SELECT [EXIT] key to return to the Amenu 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 parameter A6. The adjustment
procedure for these parameters is identical to the space
heating start triggers described above.
Display Timeout
This is the time in which the display remains illuminated.
The range is 10 seconds to 10 minutes. The default is 3
minutes.
NOTICE The internal clock does not adjust for
Daylight Savings Time and therefore,
will require a manual adjustment.
Please note that the brackets ([]) denote
screen status.
NOTICE

1 Service (continued)
15
Service Manual
Tank Minimum Set Point
This setting controls the minimum user set point for the tank
temperature. The installer can adjust this by accessing
parameter D4. The minimum setting is 60°F (16°C) and the
maximum setting is the maximum tank set point (parameter
D5).
Tank Maximum Set Point
This setting controls the maximum user set point for the tank
temperature. The installer can adjust this by accessing
parameter D5. The minimum setting is the minimum tank set
point (parameter D4) and the maximum setting is 185°F (85°C).
E: Anti-Cycling
Anti-Cycling Time
Once a SH demand has been satisfied, a set amount of time must
elapse before the control will respond to a new SH 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 parameter E2. This parameter can be
changed by the installer by accessing parameter E1. The time
range for this parameter is 0 minutes to 10 minutes. The default
value is 1 minute.
Anti-Cycling Override Differential
The control will bypass the anti-cycling time if the water
temperature drops too quickly. The control will use the water
temperature the water heater was at when it shut off as the
starting point. If the 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 parameter E2. The temperature range of this
parameter is 0°F (0°C) to 54°F (30°C). The default value is 10°F
(6°C).
B: Data Logging
Reset last 10 errors
The reset last 10 errors function clears the last 10 errors log.
C: 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 either maximum firing rate or
minimum 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 original state. This parameter can only be changed by the
installer by accessing parameter C1. The time range of this
parameter is 0 to 30 minutes. The default value is 20 minutes.
D: DHW Settings
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 (parameter D3), and
finishes the call for heat when the tank temperature reaches tank
set point. This parameter can be changed by the installer by
accessing parameter D1. The temperature range of this
parameter is 68°F (20°C) to 190°F (88°C). 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 parameter D2.
Tank Set Point Differential
When a tank sensor is installed, the tank temperature must drop
this amount below the tank set point (parameter D1) before the
heater will turn on. The installer can adjust this setting by
accessing parameter D3. The minimum setting is 0° (0°C), and
the maximum is 40°F (22°C). The default setting is 6°F (3°C).

Service Manual
16
1 Service
F: Control modes
BMS Thermostat Input (Active / Inactive)
When controlling the water heater through the 0 - 10V BMS
input or through ModBus, the water heater can be enabled
one of two ways. With parameter F1 set to ACTIVE, the
water heater will be enabled by closing the Tank Thermostat
input. With parameter F1 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 (Active / Inactive)
The set point or modulation of the water heater may be
controlled through the 0 - 10V BMS input or through
ModBus. When parameter F2 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 (Active / Inactive)
When BMS is set to ACTIVE (see BMS Active / Inactive)
and the water heater is being controlled through ModBus,
set parameter F3 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 (Timeout)
The ModBus T/O is 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
parameters. This is used to prevent unwanted operation
should ModBus communication be lost. Therefore, the
ModBus commands need to be refreshed within this time
period. This parameter is adjustable by the installer by
accessing parameter F4. 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 parameter F5. The tank sensor must be
connected to the Leader water heater. The default address
is 1.
If installing the water heaters in an existing system with
existing Armor water heaters with old style controls, the
new water heaters should be programmed as the Leader
and/or the higher number addresses.
Cascade Type (L/L / EFF)
There are two (2) options for the way a Cascade divides the
load between its heaters. The first is Lead/Lag, designated
at L/L in the menu. This method will modulate the last two
(2) water heaters only. 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%. 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-last 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).

1 Service (continued)
Service Manual
17
Maximum Cascade Outlet Set Point
This parameter determines the set point used by the
individual water heaters in a Cascade. When a water heater
is commanded to fire by the Leader water heater, it will
attempt to achieve this temperature at its outlet. The
Leader water heater will limit the modulation of the water
heater 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 outlet set point,
the water heater will then modulate down on its own in
order to keep its outlet temperature within the maximum
cascade outlet 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 parameter F7. 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. The installer can adjust this time by accessing
parameter F8. 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
parameter F9. The minimum setting is 0 minutes and the
maximum setting is 10 minutes. The default is 60 seconds.
Boiler Size
Not used.
G: Circulation pumps
DHW Pump Delay
The DHW pump delay parameter sets the length of time
the pump (if connected) will run after a DHW demand has
been satisfied. This parameter is adjustable by the installer
by accessing parameter G1. The time range for this
parameter is 0 minutes to 40 minutes. The default time is
30 seconds.
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 parameter G2. The range
of this setting is 0 seconds to 40 minutes. The default
setting is 20 seconds.
H: BMS
BMS Type (Power / Set Point)
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 parameter H1 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, parameter H2 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
Minimum value (parameter H3). The default setting is 2.0V.
Volts at Maximum
When programmed for BMS control through the 0 - 10V
BMS input or through ModBus, parameter H3 should be set
to the maximum voltage signal sent to the SMART SYSTEM
control. The range of this parameter is the Minimum value
(parameter H2) 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 (H2) is set by
parameter H4. The minimum value is 0% and the maximum
is the Power at Maximum Volts setting H5. The default value
is 20%.
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 (H3) is set
by parameter H5. The minimum value is the Power at
Minimum Volts setting H4 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 (H2) is set by parameter H6.
The minimum value is 32°F (0°C) and the maximum is the
Set Point at Maximum Volts setting H7. The default value is
70°F (21°C).

1 Service
Service Manual
18
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
parameter I3. The range for this parameter is 0 cycles to
100,000 cycles. The default is 50,000 cycles.
Reset Maintenance Reminder
Once servicing has been completed, the service notification
counter should be reset. This parameter can be reset by the
installer by accessing parameter I4. Once accessed, press the
RESET key to reset the service notification counter.
Installer Name and Phone Number
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
parameter I5. When selected, another menu will appear with
PHONE and NAME.
1. 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, select the back arrow (←) character and
press the NAVIGATION dial.
4. When finished, press the RIGHT SELECT [SAVE] key
to return to the previous menu.
Please note that the brackets ([]) denote
screen status.
NOTICE
Set Point at Maximum 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 Maximum parameter (H4) is set by parameter H7.
The minimum value is the Set Point at Minimum Volts
setting H6 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, parameter H8 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, parameter H9 determines how far
below the On Volts setting H8 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 H8.
The default value is 1.0V.
I: 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
parameter I1. The time range for this parameter is 0 months
to 36 months. The default time is 0 months.
This feature has been disabled by the manufacturer. To
enable this feature change parameter I1 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 parameter I2. The time range for this parameter is
0 hours to 100,000 hours. The default time is 8,760 hours.

2 Maintenance
Service Manual
19
Maintenance and annual startup
Table 2A Service and Maintenance Schedules
Service technician
(see the following pages for instructions)
General:
• Address reported problems
• Inspect interior; clean and vacuum if
necessary;
• Clean condensate trap and fill with fresh
water
• Check for leaks (water, gas, flue,
condensate)
• Verify flue and air lines in good condition
and sealed tight
• Check system water pressure/system
piping/expansion tank
• Check control settings
• Check ignition and flame sense electrodes
(sand off any deposits; clean
and reposition)
• Check wiring and connections
• Perform start-up checkout and
performance verification per Section 10
in the Armor Installation and Operation
Manual.
• Flame inspection (stable, uniform)
• Flame signal (at least 10 microamps at
high fire)
• Clean the heat exchanger if flue
temperature is more than 54°F above
return water temperature.
• Check Delta T (Temperature Rise)
If combustion or performance
indicate need:
• Clean heat exchanger
• Remove and clean burner using
compressed air only
• Clean the blower wheel
ANNUAL START-UP
Owner maintenance
Daily
• Check water heater area
• Check pressure/temperature
gauge
Monthly
• Check vent piping
• Check air piping
• Check air and vent termination
screens
• Check relief valve
• Check condensate drain system
• Check air vents
• Check Delta T (Temperature
Rise)
Every
6 months • Check water heater piping (gas
and water) for leaks
• Operate relief valve

2 Maintenance
20
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.
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
1. Inspect any problems reported by the owner and
correct before proceeding.
Inspect water heater area
1. Verify that water heater area is free of any combustible
materials, gasoline and other flammable vapors and
liquids.
2. Verify that air intake area is free of any of the
contaminants listed in Section 1 of the Armor Water
Heater Installation and Operation 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 Water Heater Installation and Operation
Manual.
Inspect water heater interior
1. Remove the front access cover and inspect the interior
of the water heater.
2. Vacuum any sediment from inside the water heater and
components. Remove any obstructions.
Clean condensate trap
1. Inspect the condensate drain line, condensate PVC
fittings, and condensate trap.
2. Remove the PVC cap retaining screw from the PVC cap
(FIG. 2-1).
3. Remove the 2 inch PVC cap with the switch located at
the top of the trap (FIG. 2-1).
4. Remove any sediment in the trap.
5. Fill with fresh water until the water begins to pour out
of the drain.
6. Replace the cap. Press the cap onto the trap until the
cap makes contact with the drain.
7. Replace the retaining screw.
Eliminate all system or water heater leaks.
Leaking water may cause severe property
damage.
1. Inspect all water and gas piping and verify to be leak free.
2. Look for signs of leaking lines and correct any problems
found.
3. Check gas line using the procedure found in Section 7 - Gas
Connections of the Armor Water Heater Installation and
Operation Manual.
Check all piping for leaks
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.
WARNING
WARNING
WARNING
WARNING
WARNING
PVC TEE ASSEMBLY
(FACTORY SUPPLIED)
TO FLOOR
DRAIN
2” PVC CAP WITH
BLOCKED DRAIN SWITCH
RETAINING
SCREW
CONDENSATE FROM
HEAT EXCHANGER
Figure 2-1 Condensate Trap