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WARNING: If the information in
this manual is not followed exactly, a fire
or explosion may result causing property
damage, personal injury or loss of life.
-- This water heater MUST NOT be
installed in any location where gasoline or
flammable vapors are likely to be present.
-- WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electric switch; do not
use any phone in your building.
• Immediately call your gas supplier from
a near by phone. Follow the gas supplier's
instructions.
• If you cannot reach your gas supplier, call
the fire department.
• Installation and service must be performed
by a qualified installer, service agency, or
the gas supplier.
Outdoor Armor Water
Heater Installation &
Operation Manual
Models: 151 - 801
This manual must only be used by
WARNING
a qualified heating installer / service
technician. Read all instructions,
including this manual and the
Outdoor Armor Water Heater
Service Manual, before installing.
Perform steps in the order given.
Failure to comply could result in
severe personal injury, death, or
substantial property damage.
Save this manual for future reference.
OAW-I-O Rev B
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Table of Contents
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Summary of Contents for Armor 151
- Page 1 OAW-I-O Rev B Outdoor Armor Water Heater Installation & Operation Manual Models: 151 - 801 WARNING: If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life.
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Page 2: Table Of Contents
HAZARD DEFINITIONS ............ 2 4. GAS CONNECTIONS PLEASE READ BEFORE PROCEEDING ......3 Connecting Gas Supply Piping ........21 THE OUTDOOR ARMOR WATER HEATER -- HOW IT Natural Gas ..............22 WORKS ................4-6 Pipe Sizing for Natural Gas ........22 RATINGS ................ -
Page 3: Please Read Before Proceeding
Please read before proceeding When servicing the water heater – Installer – Read all instructions, including WARNING this manual and the Outdoor Armor Water • To avoid electric shock, disconnect electrical supply Heater Service Manual, before installing. before performing maintenance. -
Page 4: The Outdoor Armor Water Heater -- How It
NPT water connection that supplies hot water to the tank. The transformer provides 24V power to the integrated control. 13. Water inlet 37. Gas shutoff switch (Models 151 - 286 Only - not shown) NPT water connection that returns water from the tank to the heat exchanger. -
Page 5: Works
The Outdoor Armor Water Heater - How it works... (continued) Models 151 - 200 IMG00284 IMG00287 Rear View - Models 151 - 200 Left Side (inside unit) - Models 151 - 200 IMG00359 IMG00360 Left Side (inside unit) - Model 286 Rear View - Model 286... - Page 6 Outdoor Armor Water Heater Installation & Operation Manual The Outdoor Armor Water Heater - How it works... Models 400 - 501 IMG00396 IMG00395 Left Side (inside unit) - Models 400 - 501 Rear View - Models 400 - 501 Models 601 - 801...
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Page 7: Ratings
1" Maximum allowed working pressure is located on the rating plate. NOTICE Notes: 1. Outdoor Armor water heaters are supplied with special gas venting materials. Use only the method of installation specified in the Outdoor Armor Installation and Operation Manual. -
Page 8: Determine Water Heater Location
• National Electrical Code. damage to controls. Locate unit at least 3 feet (0.91m) from any wall or vertical The outdoor Armor water heater gas NOTICE surface to prevent wind conditions from manifold and controls met safe lighting and affecting performance. -
Page 9: Provide Clearances
(continued) Flooring and foundation Provide clearances: Flooring Clearances from combustible materials The outdoor Armor water heater is approved for installation on Hot water pipes—at least 1/4" (6mm) from combustible combustible flooring. materials. Do not install the water heater on carpeting WARNING Vent pipes—minimum of 14"... -
Page 10: Prepare Water Heater
Outdoor Armor Water Heater Installation & Operation Manual Prepare water heater Remove water heater from wood pallet Figure 2-2 Install Flue Pipe Assembly - Models 151 - 601 WALL STRAP SCREWS 1. After removing the outer shipping carton from the water BIRD SCREEN WALL STRAP heater, remove the installation kit. -
Page 11: Gas Conversions
Installation & Operation Manual Prepare water heater (continued) Gas conversions Figure 2-4 Installing Propane Orifice - Models 151 - 286 For a water heater already installed, you WARNING must turn off gas supply, turn off power and allow the water heater to cool before proceeding. -
Page 12: Leveling The Water Heater
Outdoor Armor Water Heater Installation & Operation Manual Prepare water heater Figure 2-5 Installing Propane Orifice - Model 400 4. Use a combustion analyzer to verify CO is within the range of 9.6 – 10.5%. If not, adjust the screw counterclockwise... -
Page 13: System Piping
Installation & Operation Manual System piping System water piping methods Figure 3-1 Pump Cover Installation - Models 151 - 286 Observe a minimum of 1/4 inch clearance around all SCREWS (10X) un-insulated hot water pipes when openings around the pipes are not protected by non-combustible materials. -
Page 14: Flow Switch Adjustment
Installation & Operation Manual System piping Turn the sensitivity screw clockwise to increase Attach the paddle to the flow switch per the manufacturer’s NOTICE the flow rate required to activate the switch. instructions. Reference Table 3A to select the Turn the sensitivity screw counterclockwise to correct paddle for the pipe size used (consult the decrease the flow rate required to activate the manufacturer’s instructions for a detailed explanation). -
Page 15: Water Chemistry
Installation & Operation Manual System piping (continued) Piping components The following chart (Table 3B) details the relationship of water temperature and time with regard to scald injury and may be Water heater system piping: used as a guide in determining the safest water temperature for Water heater system piping MUST be sized per the pipe your applications. - Page 16 Installation & Operation Manual System piping Figure 3-6 Single Heater - Single Tank BUILDING FLOW CHECK RETURN VALVE (TYPICAL) BALL VALVE (TYPICAL) COLD WATER WATER SUPPLY HEATER CIRCULATOR MIXING VALVE WATER HEATER THERMOMETER HOT WATER SUPPLY UNION (TYPICAL) TEMPERATURE & PRESSURE RELIEF VALVE FLOW SWITCH STORAGE...
- Page 17 Installation & Operation Manual System piping (continued) Figure 3-7 Single Heater - Single Tank (2 Temperature) FLOW CHECK VALVE (TYPICAL) 180° HOT HIGH TEMPERATURE THERMOMETER WATER BUILDING RETURN (TYPICAL) SUPPLY UNION BALL VALVE 140° HOT (TYPICAL) (TYPICAL) MIXING WATER VALVE TEMPERATURE WATER HEATER SUPPLY...
- Page 18 Outdoor Armor Water Heater Installation & Operation Manual System piping Figure 3-8 Single Heater - Double Tank BALL VALVE (TYPICAL) BUILDING FLOW CHECK RETURN VALVE (TYPICAL) EXPANSION TANK COLD WATER SUPPLY WATER HEATER CIRCULATOR MIXING VALVE FLOW SWITCH THERMOMETER HOT WATER...
- Page 19 Outdoor Armor Water Heater Installation & Operation Manual System piping (continued) Figure 3-9 Double Heater - Single Tank Number of Units Model Required Pipe Sizes in NPT 1 1/2" 2" 2" 2" 2 1/2" 3" 3" 1 1/2" 2" 2 1/2" 2 1/2"...
- Page 20 Outdoor Armor Water Heater Installation & Operation Manual System piping Figure 3-10 Double Heater - Double Tank Number of Units Model Required Pipe Sizes in NPT 1 1/2" 2" 2" 2" 2 1/2" 3" 3" 1 1/2" 2" 2 1/2" 2 1/2"...
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Page 21: Gas Connections
Install ground joint union for servicing, when required. SEDIMENT TRAP/ On Models 151 - 400 install a manual shutoff valve in DRIP LEG the gas supply piping outside water heater jacket when required by local codes or utility requirements. -
Page 22: Natural Gas
ANSI Z223.1 (or B149.1 for Canadian installations). personal injury, death, or substantial property damage. Natural gas supply pressure requirements Outdoor Armor water heaters are typically WARNING 1. Pressure required at the gas valve inlet pressure port: shipped ready to fire on natural gas. Check •... -
Page 23: Check Inlet Gas Supply
5130 4720 Outdoor Armor water heaters are typically shipped ready to fire on natural gas. Check the water heater rating WARNING plate to determine which fuel the water heater is set for. If set to natural gas, it may be converted to LP by installing an orifice or by making a gas valve adjustment (see pages 11 and 12). -
Page 24: Gas Pressure
(FIELD SUPPLIED) FOR THE MANOMETER TUBING. Figure 4-6 Inlet Gas Supply Check - Models 151 - 286 LOOSEN THE SET SCREW ONE (1) FULL TURN AND PLACE THE MANOMETER TUBING OVER THE PRESSURE TAP... -
Page 25: Field Wiring
National 3. The DHW (water heater) pump is shipped loose on all Electrical Code ANSI/NFPA 70 – latest Armor models. Wire the water heater pump as shown in edition. FIG. 5-1. All wiring exterior to the appliance must 4. -
Page 26: Flow Switch
Outdoor Armor Water Heater Installation & Operation Manual Field wiring Tank thermostat Flow switch 1. Connect the tank thermostats (isolated contact only) to 1. A flow switch is used to guarantee flow through the water the tank thermostat contacts as shown in FIG. 5-3. -
Page 27: Runtime Contacts
Outdoor Armor Water Heater Installation & Operation Manual Field wiring (continued) Runtime contacts The SMART SYSTEM control closes a set of dry contacts whenever the burner is running. This is typically used by Building Management Systems to verify that the water heater is responding to a call for heat. - Page 28 Outdoor Armor Water Heater Installation & Operation Manual Field wiring Figure 5-3 Low Voltage Field Wiring Connections...
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Page 29: Condensate Disposal
A Neutralizer Kit (FIG. 6-1) is available from the factory condensate. If condensate is allowed to (KIT3087 for Models 151 - 501 and KIT3046 for Models freeze in the line or if the line is obstructed 601 - 801). in any other manner, condensate can exit from the water heater tee, resulting in 4. -
Page 30: Startup
Outdoor Armor Water Heater Installation & Operation Manual Start-up Chlorine concentration less than 200 ppm Propane water heaters only – Your propane WARNING supplier mixes an odorant with the propane 1. Do not fill the water heater or operate with water to make its presence detectable. -
Page 31: Final Checks Before Starting The Water Heater
Check vent piping and air piping heater 1. Check for gastight seal at every connection, seam of air Read the Outdoor Armor Water Heater Service Manual piping, and vent piping. to familiarize yourself with SMART SYSTEM control Venting system must be sealed gastight WARNING module operation. -
Page 32: For Your Safety Read Before Operating
Outdoor Armor Water Heater Installation & Operation Manual Start-up Figure 7-2 Operating Instructions - Models 151 - 286 FOR YOUR SAFETY READ BEFORE OPERATING WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury, or loss of life. - Page 33 Outdoor Armor Water Heater Installation & Operation Manual Start-up (continued) Figure 7-3 Operating Instructions - Models 400 - 801...
- Page 34 3.0% - 6.5% 9.0% - 11% 4.1% - 6.9% the Outdoor Armor Water Heater Service Manual for a detailed explanation of this procedure. Once the combustion analysis is complete, test the safety shutoff device by turning the manual shutoff valve to the OFF position and ensuring that the water heater shuts down and registers an alarm.
- Page 35 4 hours. Use the following procedure to set the clock: Press the [MENU] key for at least five (5) seconds. Input the Installer code as described in the Outdoor Armor Service Press and hold the LEFT SELECT [MENU] key for at Manual.
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Page 36: Operating Information
The control monitors the temperature difference between to the water tank. If a tank sensor is connected, the SMART the inlet and the outlet sensor. On Models 151 - 501 if this SYSTEM control will ignore the tank thermostat. difference is between 25 - 30°F the control will reduce the fan speed. -
Page 37: Water Heater Temperature Regulation
To enable this feature change the parameter 10. Once the outlet temperature rises up to the MRHL set to the desired time interval, reference the Outdoor Armor point, the MRHL will function, causing the water heater to Service Manual for details regarding parameters. -
Page 38: Cascade
24 hours. The switching on/off See the Outdoor Armor Water Heater Service Manual for a sequence will be as follows: detailed description of parameters and access modes. -
Page 39: Sequence Of Operation
Outdoor Armor Water Heater Installation & Operation Manual Operating information (continued) Sequence of operation OPERATION DISPLAY 1. The control will turn on the water heater pump (always ON except in Night Setback). The flow switch and/or LWCO must close. 2. Air pressure switch and blocked drain switch must close. -
Page 40: Outdoor Armor Water Heater Control Module
Outdoor Armor Water Heater Installation & Operation Manual Operating information Outdoor Armor water heater control module Use the control panel (FIG. 8-1) to set temperatures, operating conditions, and monitor water heater operation. Figure 8-1 Control Panel The information on the bottom of the display shows the functions of the two SELECT keys (on either corner), and the... -
Page 41: Status Display Screens
Outdoor Armor Water Heater Installation & Operation Manual Operating information (continued) Figure 8-2 Status Display Screen Status Display Screens Section Display Description The unit has not received a call for heat from a remote thermostat nor STANDBY has it received a call for heat from a DHW thermostat. -
Page 42: Status Display Screens
Outdoor Armor Water Heater Installation & Operation Manual Operating information Status Display Screens (cont’d) Section Display Description TANK: The temperature read by the tank sensor (if connected). INLET TEMP: The temperature read at the inlet to the heat exchanger. OUTLET TEMP: The temperature read at the outlet of the heat exchanger. - Page 43 Outdoor Armor Water Heater Installation & Operation Manual Operating information (continued) Status Display Screens (cont’d) Section Display Description Turning the NAVIGATION dial will select the next or previous Status Screen. Pressing the NAVIGATION dial will show the next fault, NSB (Night Setback) trigger, or ramp delay setting.
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Page 44: Maintenance
Outdoor Armor Water Heater Installation & Operation Manual Maintenance Maintenance and annual startup Table 9A Service and Maintenance Schedules Service technician Owner maintenance (see the following pages for instructions) General: • Address reported problems • Inspect interior; clean and vacuum if Daily •... -
Page 45: Address Reported Problems
Outdoor Armor Water Heater Installation & Operation Manual Maintenance (continued) Follow the service and maintenance procedures given throughout this manual and in component literature WARNING shipped with the water heater. Failure to perform the service and maintenance could result in damage to the water heater or system. -
Page 46: Check Water System
Outdoor Armor Service Manual. Adjust settings if – not by the owner. Failure to re-inspect necessary. See Section 1 of the Outdoor Armor Service the water heater relief valve as directed Manual for adjustment procedures. -
Page 47: Check Burner Flame
3. See Section 3 - Troubleshooting in the Outdoor Armor valves to allow water to flow through the water make-up Service Manual for other procedures to deal with low line to the water heater. -
Page 48: Check Delta T
CTN20005 Rear Refractory Cover 1. The circulator shipped with the outdoor water heater is MSC20083* Nylon 4" Wheel Brush* water-lubricated. No oiling is required. 151 - 400 KIT30063 MSC20084 3mm Allen Wrench 2. Check other circulators in the system. Oil any circulators requiring oil, following circulator manufacturer’s... -
Page 49: Diagrams
Outdoor Armor Water Heater Installation & Operation Manual Diagrams Figure 10-1 Ladder Diagram JUNCTION BOX 120VAC NEUTRAL GROUND TERMINAL STRIP TERMINAL STRIP 120V SUPPLY "L" 120V SUPPLY "N" INTEGRATED CONTROL ON / OFF SWITCH X1-1 X1-6 BLOWER 3.15A X1-2 BUILDING... -
Page 50: Wiring Diagram
Outdoor Armor Water Heater Installation & Operation Manual Diagrams Figure 10-2 Wiring Diagram LOW VOLTAGE BOX DEPICTS 120 VAC OPTIONAL ITEMS HIGH VOLTAGE BOX DEPICTS DUAL SENSOR SINGLE HOUSING INTEGRATED CONNECTION BOARD CONTROL JUNCTION ALARM X1-3 OR/BK CONTACTS RUN-TIME PUMP... - Page 51 Installation & Operation Manual OUTDOOR CONDENSING WATER HEATER Notes...
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Page 52: Revision Notes
Revision Notes: Revision A (ECO #C10942) initial release. Revision B (ECO #C11235) reflects updates made to the freezing conditions warnings. OAW-I-O Rev B 10/12...
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