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Installation & Operation Manual
4
The Armor Water Heater - How it works...
1. Stainless steel heat exchanger
Allows water to flow through specially designed
coils for maximum heat transfer, while providing
protection against flue gas corrosion. The coils are
encased in a jacket that contains the combustion process.
2. Heat exchanger access cover
Allows access to the combustion side of the heat exchanger coils.
3. Blower
The blower pulls in air and gas through the venturi
(item 5). Air and gas mix inside the blower and are pushed into
the burner, where they burn inside the combustion chamber.
4. Gas valve
The gas valve senses the negative pressure created by the
blower, allowing gas to flow only if the gas valve is
powered and combustion air is flowing.
5. Venturi
The venturi controls air and gas flow into the burner.
6. Flue gas sensor
This sensor monitors the flue gas exit temperature. The control
module will modulate and shut down the water heater if the
flue gas temperature gets too hot. This protects the flue pipe
from overheating.
7. Water heater outlet temperature sensor
This sensor monitors water heater outlet water temperature.
8. Water heater inlet temperature sensor
This sensor monitors return water temperature (system
return). If selected as the controlling sensor, the control
module adjusts the water heater firing rate so the inlet
temperature is correct.
9. Flow Switch
The flow switch is a safety device that ensures flow through the
heat exchanger during operation. This appliance is low mass
and should never be operated without flow. The flow switch
makes contact when flow is detected and allows the unit to
operate. If flow is discontinued during operation for any reason
the flow switch will break the control circuit and the unit will
shut down.
10. Electronic display
The electronic display consists of 7 buttons and a dual line 32-
character liquid crystal display.
11. Flue pipe adapter
Allows for the connection of the PVC vent pipe system to the
water heater.
12. Burner (not shown)
Made with metal fiber and stainless steel construction,
the burner uses pre-mixed air and gas and provides a
wide range of firing rates.
13. Water outlet
NPT water connection that supplies hot water to the tank.
14. Water inlet
NPT water connection that returns water from the tank to the heat
exchanger.
15. Gas connection pipe
Threaded pipe connection. This pipe should be connected
to the incoming gas supply for the purpose of delivering
gas to the water heater.
16. SMART Control Module
The SMART Control responds to internal and external signals
and controls the blower, gas valve, and pumps to meet the
demand.
17. Automatic air vent
Designed to remove trapped air from the heat exchanger
coils.
18. Air intake adapter
Allows for the connection of the PVC air intake pipe to
the water heater.
19. Line voltage junction box
The junction box contains the connection points for the line
voltage power and the pump.
20. Water heater drain port
Location from which the heat exchanger can be drained.
21. Low voltage connection board
The connection board is used to connect external low voltage
devices.
22. Low voltage wiring connections (knockouts)
Conduit connection points for the low voltage
connection board.
23. Condensate drain connection
Connects the condensate drain line to a 1/2" PVC union.
24. Access cover - front (not shown)
Provides access to the gas train and the heat exchanger.
25. Ignition electrode
Provides direct spark for igniting the burner.
26. Flame inspection window
The quartz glass window provides a view of the burner
surface and flame.
27. Gas shutoff valve
Manual valve used to isolate the gas valve from the gas supply.
28. High limit sensor
Device that monitors the outlet water temperature. If the
temperature exceeds its setting, it will break the control circuit,
shutting the water heater down.
29. Relief valve
Protects the heat exchanger from over pressure and
temperature conditions. The relief valve is set at 150 PSI.
30. Flame sensor
Used by the control module to detect the presence of burner
flame.
31. Line voltage wiring connections (knockouts)
Conduit connection points for the high voltage junction box.
32. Top panel
Removable panel to gain access to the internal components.
33. Power switch
Turns 120 VAC ON/OFF to the water heater.
34. Leveling legs
Used to allow the heat exchanger to be leveled. This is needed
for the proper draining of the condensate from the combustion
chamber.
35. Air shroud (500 Model Only)
The air shroud directs air and gas flow into the burner.
36. Air pressure switch
The air pressure switch detects blocked inlet or outlet
conditions.
37. Pump relay (not shown)
The pump relay is used to control the circulation pump.