Lochinvar 150 - 500, Armor AWN150PM, Armor AWN199PM, Armor AWN285PM, Armor AWN399PM Operation Manual

...

Installation & Operation

Manual

Models: 150 - 500

Starting Serial #H07H10046464

This manual must only be used by a qualified heating installer / service technician. Read all instructions, including this manual and the 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.

 WARNING

Save this manual for future reference.

AW-I-O Rev I

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.

HAZARD DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2

PLEASE READ BEFORE PROCEEDING . . . . . . . . . . . . 3

THE ARMOR WATER HEATER -- HOW IT WORKS . . . . 4

RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1. DETERMINE WATER HEATER LOCATION

Provide Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Provide Air Openings to Room . . . . . . . . . . . . . . . . . . . . 10

Flooring and Foundation . . . . . . . . . . . . . . . . . . . . . . . . 10

Residential Garage Installation . . . . . . . . . . . . . . . . . . . . 10

Vent and Air Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Prevent Combustion Air Contamination . . . . . . . . . . . . . . 10

Corrosive Contaminants and Sources . . . . . . . . . . . . . . . 11

Removing a Water Heater from Existing Common Vent . 11

2. PREPARE WATER HEATER

Remove Water Heater from Wood Pallet . . . . . . . . . . . . 12

Gas Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Leveling the Water Heater . . . . . . . . . . . . . . . . . . . . . 13

3. GENERAL VENTING

Direct Venting Options . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Install Vent and Combustion Air Piping . . . . . . . . . . . . . . 15

Vent Piping Materials . . . . . . . . . . . . . . . . . . . . . . . . . 15

Requirements for Installation in Canada . . . . . . . . . . . . . 15

Air Intake/Vent Connections . . . . . . . . . . . . . . . . . . . . . . 16

Air Inlet Pipe Materials . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Min./Max. Combustion Air & Vent Piping Lengths . . . . . . 17

Removing from Existing Vent . . . . . . . . . . . . . . . . . . . . . 17

Vent and Air Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4. SIDEWALL DIRECT VENTING

Vent/Air Termination - Sidewall . . . . . . . . . . . . . . . . . . . . 18-21

Determine Location . . . . . . . . . . . . . . . . . . . . . . . . . . 18-19

Prepare Wall Penetrations . . . . . . . . . . . . . . . . . . . . . 20

Termination and Fittings . . . . . . . . . . . . . . . . . . . . . . . 20

Multiple Vent/Air Terminations . . . . . . . . . . . . . . . . . . 20

Sidewall Termination - Optional Concentric Vent . . . . . . 21-23

5. VERTICAL DIRECT VENTING

Vent/Air Termination - Vertical . . . . . . . . . . . . . . . . . . . . . 24-25

Determine Location . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Prepare Roof Penetrations . . . . . . . . . . . . . . . . . . . . . 25

Termination and Fittings . . . . . . . . . . . . . . . . . . . . . . . 25

Multiple Vent/Air Terminations . . . . . . . . . . . . . . . . . . 25

Vertical Termination - Optional Concentric Vent . . . . . . . 26-27

6. HYDRONIC PIPING

System Water Piping Methods . . . . . . . . . . . . . . . . . . . . 28

Flow Switch and Relief Valve Installation . . . . . . . . . . . . 28

Flow Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Water Chemistry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Piping Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

7. GAS CONNECTIONS

Connecting Gas Supply Piping . . . . . . . . . . . . . . . . . . . . 35

Natural Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Pipe Sizing for Natural Gas . . . . . . . . . . . . . . . . . . . . 36

Natural Gas Supply Pressure Requirements . . . . . . . 36

Propane Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Pipe Sizing for Propane Gas . . . . . . . . . . . . . . . . . . . 36

Propane Supply Pressure Requirements . . . . . . . . . . 36

Check Inlet Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

High and Low Gas Pressure Switches . . . . . . . . . . . . . . 38

Gas Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 38

8. FIELD WIRING

Line Voltage Connections . . . . . . . . . . . . . . . . . . . . . . . . 39

Low Voltage Connections . . . . . . . . . . . . . . . . . . . . . . . . 40

Wiring of the Cascade . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

9. CONDENSATE DISPOSAL

Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

10. STARTUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44-49

11. OPERATING INFORMATION

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Cascade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51-52

Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Armor Water Heater Control Module . . . . . . . . . . . . . . . . 54

Status Display Screens . . . . . . . . . . . . . . . . . . . . . . . . . . 55-57

12. MAINTENANCE

Maintenance & Annual Startup . . . . . . . . . . . . . . . . . . . . 58-61

13. DIAGRAMS

Ladder Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Revision Notes . . . . . . . . . . . . . . . . . . . . . . . . . Back Cover

Contents

Installation & Operation Manual

Please read before proceeding

Installer – Read all instructions, including this manual and the Armor Water Heater Service 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.

Failure to adhere to the guidelines on this page can result in severe personal injury, death, or substantial property damage.

When servicing the 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.

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.

Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee.

Factory warranty (shipped with unit) does not apply to units improperly installed or improperly operated.

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.

 WARNING

NOTICE

 WARNING

Installation & Operation Manual

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 32character 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 system, either 1-1/4" or 2", depending on the model.

14. Water inlet

NPT water connection that returns water from the system to the heat exchanger, either 1-1/4" or 2", depending on the model.

15. Gas connection pipe

Threaded pipe connection, either 1/2", 3/4", or 1", depending on the model. 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

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 may be set at 125 or 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

The air shroud controls air and gas flow into the burner.

36. Air pressure switch

The air pressure switch detects blocked inlet conditions.

Installation & Operation Manual

Front View - Models 150 - 285

Left Side (inside unit) - Models 150 - 285

Right Side (inside unit) - Models 150 - 285

The Armor Water Heater - How it works... (continued)

Rear View - Models 150 - 285

Models 150 - 285

4 5

Installation & Operation Manual

The Armor Water Heater - How it works...

Rear View - Model 399

Rear View - Model 500

Left Side (inside unit) - Model 500

Left Side (inside unit) - Model 399

Model 399

Model 500

Installation & Operation Manual

Ratings

Notes:

1. Armor water heaters require special gas venting. Use only the vent materials and methods specified in the Armor Installation and Operation Manual.

2. Standard Armor water heaters are equipped for operation up to 4,500 feet with no field adjustments. Output ratings will be reduced by 4% for each 1,000 feet above sea level up to 4,500 feet only.

3. High altitude Armor water heaters will have a high altitude label affixed to the unit (as shown in FIG. A) and are equipped for operation of 4,501 feet to 12,000 feet only with no field adjustments. For high altitude models, output ratings will be reduced by 2% for each 1,000 feet above sea level.

High altitude models have a different control module for altitude operation, but the operation given in this manual for standard models remains the same.

Maximum allowed working pressure is located on the rating plate.

Model Number

Note: Change “N” to

“L” for L.P. gas models.

CSA

Input Modulation Btu/hr

Water Content

Gallons

Water

Connections

Gas

Connections

Vent/Air Size

(Note 2, 3) (Note 1)

AWN150PM 30,000 - 150,000 1.3 1-1/4" 1/2" 3"

AWN199PM 40,000 - 199,999 1.7 1-1/4" 1/2" 3"

AWN285PM 57,000 - 285,000 2.4 2" 3/4" 4"

AWN399PM 80,000 - 399,999 3.4 2" 1" 4"

AWN500PM 100,000 - 500,000 4.2 2" 1" 4"

NOTICE

Figure A High Altitude Label Location

UNIT EQUIPPED FOR

HIGH ALTITUDE

4,501 FT. TO 12,000 FT.

Installation & Operation Manual

1 Determine water heater location

The Armor water heater gas manifold and controls met safe lighting and other performance under tests specified in ANSI Z21.10.3 – latest edition.

Failure to keep water heater area clear and free of combustible materials, gasoline, and other flammable liquids and vapors can result in severe personal injury, death, or substantial property damage.

Installation must comply with:

• Local, state, provincial, and national codes, laws, regulations, and ordinances.

• National Fuel Gas Code, ANSI Z223.1 – latest edition.

• National Electrical Code.

• For Canada only: B149.1 Installation Code, CSA C22.1 Canadian Electrical Code Part 1 and any local codes.

Before locating the water heater, check:

1. Check for nearby connection to:

• Water piping

• Venting connections

• Gas supply piping

• Electrical power

2. Locate the appliance so that if water connections should

leak, water damage will not occur. When such locations cannot be avoided, it is recommended that a suitable drain pan, adequately drained, be installed under the appliance. The pan must not restrict combustion air flow. Under no circumstances is the manufacturer to be held responsible for water damage in connection with this appliance, or any of its components.

3. Check area around the water heater. Remove any

combustible materials, gasoline and other flammable liquids.

4. The Armor water heater must be installed so that gas control

system components are protected from dripping or spraying water or rain during operation or service.

5. If a new water heater will replace an existing water heater,

check for and correct system problems, such as:

• System leaks causing oxygen corrosion or heat exchanger cracks from hard water deposits.

 WARNING

This appliance is certified as an indoor appliance. Do not install the appliance outdoors or locate where the appliance will be exposed to freezing temperatures or to temperatures that exceed 100°F.

Failure to install the appliance indoors could result in severe personal injury, death, or substantial property damage.

Provide clearances:

Clearances from combustible materials

1. Hot water pipes—at least 1" from combustible materials.

2. Vent pipe – at least 1" from combustible materials.

3. See FIG.’s 1-1 and 1-2 on page 9 for other clearance minimums.

Clearances for service access

1. See FIG.’s 1-1 and 1-2 on page 9 for recommended

service clearances. If you do not provide the minimum clearances shown, it may not be possible to service the water heater without removing it from the space.

Closet and alcove installations

This appliance requires a special venting system. The vent connection to the appliance must be made with the starter CPVC pipe section provided with the appliance. The field provided vent fittings must be cemented to the CPVC pipe section. Use only the vent materials, primer and cement specified in this manual to make the vent connections. Failure to follow this warning could result in fire, personal injury, or death.

For closet and alcove installations as shown in FIG.’s 1-1 and 1-2, CPVC vent material must be used inside the structure. The ventilating air openings shown in FIG.’s 1-1 and 1-2 are required for this arrangement. Failure to follow this warning could result in fire, personal injury, or death.

 WARNING

NOTICE

 WARNING

A closet is any room the water heater is installed in which is less than 86 cubic feet for AWN150 models, 106 cubic feet for AWN199 models, 120 cubic feet for AWN285 models, 165 cubic feet for AWN399 models and 191 cubic feet for AWN500 models.

An alcove is any room which meets the criteria for a closet with the exception that it does not have a door.

Example: Room dimensions = 4 feet long, 5 feet wide, and 9 foot ceiling = 4 x 5 x 9 = 180 cubic feet. This would be considered a closet for a Armor Water Heater.

Installation & Operation Manual

1 Determine water heater location (continued)

Figure 1-2 Alcove Installation - Minimum Required Clearances

Figure 1-1 Closet Installation - Minimum Required Clearances

 WARNING

For closet installations, CPVC material MUST BE used in a closet structure due to elevated temperatures. Failure to follow this warning could result in fire, personal injury, or death.

 WARNING

For alcove installations, CPVC material MUST BE used in an alcove structure due to elevated temperatures. Failure to follow this warning could result in fire, personal injury, or death.

RECOMMENDED SERVICE CLEARANCES:

FRONT - 24” TOP - 24” LEFT SIDE - 24” REAR - 24”

RECOMMENDED SERVICE CLEARANCES:

FRONT - 24” TOP - 24” LEFT SIDE - 24” REAR - 24”

Installation & Operation Manual

1 Determine water heater location

Provide air openings to room:

Armor water heater alone in equipment room

1. No air ventilation openings into the equipment room are needed when clearances around the Armor water heater are at least equal to the SERVICE clearances shown in FIG.’s 1-1 and 1-2. For spaces that do NOT supply this clearance, provide two openings as shown in FIG. 1-1. Each opening must provide one square inch free area per 1,000 Btu/hr of water heater input.

Armor water heater in same space with other gas or oil-fired appliances

1. Follow the National Fuel Gas Code (U.S.) or CSA B149.1 (Canada) to size/verify size of the combustion/ventilation air openings into the space.

The space must be provided with combustion/ventilation air openings correctly sized for all other appliances located in the same space as the Armor water heater.

Do not install the water heater in an attic.

Failure to comply with the above warnings could result in severe personal injury, death, or substantial property damage.

2. Size openings only on the basis of the other appliances in the space. No additional air opening free area is needed for the Armor water heater because it takes its combustion air from outside (direct vent installation).

Do not install the water heater on carpeting even if foundation is used. Fire can result, causing severe personal injury, death, or substantial property damage.

If flooding is possible, elevate the water heater sufficiently to prevent water from reaching the water heater.

Flooring and foundation

Flooring

The Armor water heater is approved for installation on combustible flooring, but must never be installed on carpeting.

Residential garage installation

Precautions

Take the following precautions when installing the appliance in a residential garage. If the appliance is located in a residential garage, it should be installed in compliance with the latest edition of the National Fuel Gas Code, ANSI Z223.1 and/or CAN/CGA-B149 Installation Code.

• Appliances located in residential garages and in adjacent spaces that open to the garage and are not part of the living space of a dwelling shall be installed so that all burners and burner ignition devices are located not less than 18 inches (46 cm) above the floor.

• The appliance shall be located or protected so that it is

not subject to physical damage by a moving vehicle.

Vent and air piping

The Armor water heater requires a special vent system, designed for pressurized venting.

You must also install air piping from outside to the water heater air intake adapter. The resultant installation is direct vent (sealed combustion). Note prevention of combustion air contamination below when considering vent/air termination.

Vent and air must terminate near one another and may be vented vertically through the roof or out a side wall. You may use any of the vent/air piping methods covered in this manual. Do not attempt to install the Armor water heater using any other means.

Be sure to locate the water heater such that the vent and air piping can be routed through the building and properly terminated. The vent/air piping lengths, routing and termination method must all comply with the methods and limits given in this manual.

Prevent combustion air contamination

Install air inlet piping for the Armor water heater as described in this manual. Do not terminate vent/air in locations that can allow contamination of combustion air. Refer to Table 1A, page 11 for products and areas which may cause contaminated combustion air.

You must pipe combustion air to the water heater air intake. Ensure that the combustion air will not contain any of the contaminants in Table 1A, page 11. Contaminated combustion air will damage the water heater, resulting in possible severe personal injury, death or substantial property damage. Do not pipe combustion air near a swimming pool, for example. Also, avoid areas subject to exhaust fumes from laundry facilities. These areas will always contain contaminants.

 WARNING

Installation & Operation Manual

1 Determine water heater location (continued)

Products to avoid:

Spray cans containing chloro/fluorocarbons

Permanent wave solutions

Chlorinated waxes/cleaners

Chlorine-based swimming pool chemicals

Calcium chloride used for thawing

Sodium chloride used for water softening

Refrigerant leaks

Paint or varnish removers

Hydrochloric acid/muriatic acid

Cements and glues

Antistatic fabric softeners used in clothes dryers

Chlorine-type bleaches, detergents, and cleaning solvents found in household laundry rooms

Adhesives used to fasten building products and other similar products

Areas likely to have contaminants

Dry cleaning/laundry areas and establishments

Swimming pools

Metal fabrication plants

Beauty shops

Refrigeration repair shops

Photo processing plants

Auto body shops

Plastic manufacturing plants

Furniture refinishing areas and establishments

New building construction

Remodeling areas

Garages with workshops

Table 1A Corrosive Contaminants and Sources

When removing a water heater from existing common vent system:

Do not install the Armor water heater into a common vent with any other appliance. This will cause flue gas spillage or appliance malfunction, resulting in possible severe personal injury, death, or substantial property damage.

Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death.

At the time of removal of an existing water heater, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation.

a. Seal any unused openings in the common venting system.

b. Visually inspect the venting system for proper size and

horizontal pitch and determine there is no blockage or restriction, leakage, corrosion, or other deficiencies, which could cause an unsafe condition.

c. Test vent system – Insofar as is practical, close all building

doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryers and any appliance not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers.

d. Place in operation the appliance being inspected. Follow

the lighting instructions. Adjust thermostat so appliance will operate continuously.

e. Test for spillage at the draft hood relief opening after

5 minutes of main burner operation. Use the flame of a match or candle, or smoke from a cigarette, cigar, or pipe.

f. After it has been determined that each appliance

remaining connected to the common venting system properly vents when tested as outlined herein, return doors, windows, exhaust fans, fireplace dampers, and any other gas-burning appliance to their previous conditions of use.

g. Any improper operation of the common venting system

should be corrected so the installation conforms with the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or CAN/CSA B149.1, Natural Gas and Propane Installation Code. When resizing any portion of the common venting system, the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Part 11 of the National Fuel Gas Code, ANSI Z223.1/NFPA and/or CAN/CSA B149.1, Natural Gas and Propane Installation Code.

 DANGER

 WARNING

Installation & Operation Manual

2 Prepare water heater

Figure 2-2 Installing Propane Orifice - Models 150 - 285

Remove water heater from wood pallet

1. After removing the outer shipping carton from the water heater, remove the parts box.

2. Remove the front door to access the lag bolts in front of the unit (FIG. 2-1).

3. To remove the water heater from the pallet (after removing the front door):

a. Remove the two lag bolts from the wood pallet

inside the water heater (FIG. 2-1).

b. Detach the water heater from the lag bolts in the rear of

the unit, see FIG. 2-1.

Do not drop the water heater or bump the jacket on the floor or pallet. Damage to the water heater can result.

For a water heater already installed, you must turn off gas supply, turn off power and allow the water heater to cool before proceeding. You must also completely test the water heater after conversion to verify performance as described under Start-up, Section 10 of this manual. Failure to comply could result in severe personal injury, death, or substantial property damage.

For Models 150 - 399 you must install a propane orifice to operate the Armor water heater on propane gas. Verify when installing that the orifice size marking matches water heater size (Models 150 – 399, Table 2A).

The 500 Model does not require an orifice installation for propane operation, but it will require a valve adjustment.

Models 150 - 285

1. Remove the top and front access covers from the unit (no tools required for removal).

2. Remove the three screws securing the gas valve to the venturi (FIG. 2-2).

3. Locate the propane orifice disk from the conversion kit bag. Verify that the stamping on the orifice disk matches the water heater size (150 – 285) (see Table 2A above).

Place the orifice into the black rubber grommet in the side of the gas valve and secure in the valve (FIG. 2-2).

4. Reposition the gas valve against the venturi and replace the screws (FIG. 2-2) securing the valve to the venturi.

5. After installation is complete, attach the propane conversion label (in the conversion kit bag) next to the water heater rating plate. Attach the LP caution label (in the conversion kit bag) to the left side of the unit in the lower left corner.

6. Replace the top and front access covers.

Figure 2-1 Water heater Mounted on Shipping Pallet

Gas conversions

LP Conversion Table

Model LP Orifice Stamping

150

199

210 / W150

285

399

8.0

NOTICE

 WARNING

Table 2A LP Conversion Table

 WARNING

After converting to LP, check combustion per the Start-up procedure in Section 10 of this manual. Failure to check and verify combustion could result in severe personal injury, death, or substantial property damage.

Installation & Operation Manual

2 Prepare water heater (continued)

Figure 2-3 Installing Propane Orifice - Model 399

Figure 2-5 Leveling Legs on the Water Heater

Leveling the water heater

1. Set the water heater in place and check level. a) Adjust legs if necessary to level the water heater,

see FIG. 2-5 below.

Model 399

1. Remove the top and front access covers from the unit (no tools required for removal).

2. Remove the three screws securing the venturi to the blower. Note: When separating the venturi from the blower, take care not to damage the O-ring inside the blower (FIG. 2-3).

3. Remove the four screws securing the gas valve to the venturi (FIG. 2-3).

4. Locate the propane orifice disk from the conversion kit bag. Verify that the stamping on the orifice disk matches the water heater size (see Table 2A on page 12).

5. Remove the existing orifice from the O-ring in the side of the gas valve and replace it with the orifice from the kit. Position and secure the orifice in the valve as shown in FIG. 2-3.

6. Reposition the gas valve against the venturi and replace the screws (FIG. 2-3) securing the valve to the venturi.

7. Inspect the O-ring inside the blower. Handle the O-ring with care, do not damage. Reposition the venturi against the blower and replace the screws securing the venturi to the blower (FIG. 2-3).

8. After installation is complete, attach the propane conversion label (in the conversion kit bag) next to the water heater rating plate. Attach the LP caution label (in the conversion kit bag) to the left side of the unit in the lower left corner.

9. Replace the top and front access covers.

 DANGER

Armor 399: Inspect the O-ring when the blower is disassembled. The O-ring must be in good condition and must be installed. Failure to comply will cause a gas leak, resulting in severe personal injury or death.

Figure 2-4 Gas Valve Adjustment - Model 500

Model 500

1. Remove the top access cover from the unit (no tools required for removal).

2. Turn the adjustment screw on the gas valve clockwise until it stops. Then turn the adjustment screw counterclockwise four and three quarter (4 3/4) turns (see FIG. 2-4).

3. Use a combustion analyzer to verify CO

is within the

range of 9.6 – 10.5%. If not, adjust the screw counterclockwise incrementally to raise CO

and

clockwise to lower CO

(FIG. 2-4).

4. After adjustment is complete, attach the propane conversion label (in the conversion kit bag) next to the water heater rating plate. Attach the LP caution label (in the conversion kit bag) to the left side of the unit in the lower left corner.

5. Replace the top access cover.

 WARNING

Installation & Operation Manual

3 General venting

Figure 3-1 Vertical Direct Venting (Two-Pipe Vertical

Termination) - See page 24 for more details

Figure 3-2 Sidewall Direct Venting (Two-Pipe Sidewall Termination) - See page 18 for more details

Figure 3-3 Concentric Vertical Termination - See page 26 for more details

Figure 3-4 Concentric Sidewall Termination - See page 21 for more details

Direct venting options

Installation & Operation Manual

3 General venting (continued)

Vent piping materials

Use only the materials listed in Table 3A below for vent pipe, and fittings. Failure to comply could result in severe personal injury, death, or substantial property damage.

Installation must comply with local requirements and with the National Fuel Gas Code, ANSI Z223.1 for U.S. installations or CSA B149.1 for Canadian installations.

Table 3A Vent Pipe, and Fittings

Install vent and combustion air piping

 DANGER

The Armor water heater must be vented and supplied with combustion and ventilation air as described in this section. Ensure the vent and air piping and the combustion air supply comply with these instructions regarding vent system, air system, and combustion air quality. See also Section 1 of this manual.

Inspect finished vent and air piping thoroughly to ensure all are airtight and comply with the instructions provided and with all requirements of applicable codes.

Failure to provide a properly installed vent and air system will cause severe personal injury or death.

All vent pipes must be glued, properly supported, and the exhaust must be pitched a minimum of a 1/4 inch per foot back to the water heater (to allow drainage of condensate).

This appliance requires a special venting system. The vent connection to the appliance must be made with the starter CPVC pipe section provided with the appliance. The field provided vent fittings must be cemented to the CPVC pipe section using an “All Purpose Cement” suitable for PVC and CPVC pipe. Use only the vent materials, primer, and cement specified in this manual to make the vent connections. Failure to follow this warning could result in fire, personal injury, or death.

 WARNING

NOTICE

 WARNING

For closet and alcove installations, CPVC material MUST BE used in a closet/alcove structure. Failure to follow this warning could result in fire, personal injury, or death.

NOTICE

Requirements for installation in Canada

1. Installations must be made with a vent pipe system certified to ULC-S636.

IPEX is an approved vent manufacturer in Canada supplying vent material listed to ULC-S636.

2. The first three (3) feet of plastic vent pipe from the appliance flue outlet must be readily accessible for visual inspection.

3. The components of the certified vent system must not be interchanged with other vent systems or unlisted pipe/fittings. For concentric vent installations, the inner vent tube must be replaced with field supplied certified vent material to comply with this requirement.

4. The 3" Concentric Vent Kit available from Lochinvar (see Section 4 – Sidewall Termination – Optional Concentric Ve n t) and the 3" Concentric Vent Kit available from IPEX are both approved for use on the Armor water heater. Both kits are listed to the ULC-S636 standard for use in Canada.

All vent pipe materials and fittings must comply with the following:

Item Material

Standards for installation in:

United States Canada

Vent pipe and fittings

PVC schedule 40 ANSI/ASTM D1785

CPVC and PVC venting must be ULC-S636 Certified. IPEX is an approved manufacturer in Canada supplying vent material listed to ULC-S636.

PVC-DWV ANSI/ASTM D2665

CPVC schedule 40 ANSI/ASTM F441

Pipe cement/primer

PVC ANSI/ASTM D2564

IPEX System 636

Cements & Primers

CPVC ANSI/ASTM F493

NOTICE: DO NOT USE CELLULAR (FOAM) CORE PIPE

Installation & Operation Manual

3 General venting

Air intake/vent connections

1. Combustion Air Intake Connector (FIG.’s 3-5 thru 3-7) Used to provide combustion air directly to the unit from outdoors. A fitting is provided on the unit for final connection. Combustion air piping must be supported per guidelines listed in the National Mechanical Code, Section 305, Table 305.4 or as local codes dictate.

2. Vent Connector (FIG.’s 3-5 thru 3-7) - Used to provide a passageway for conveying combustion gases to the outside. A transition fitting is provided on the unit for final connection. Vent piping must be supported per the National Building Code, Section 305, Table 305.4 or as local codes dictate.

Combustion air piping to the outside MUST BE used. Use of combustion air from the room via louvers, plenums, or any other device is not authorized.

NOTICE

3” CPVC PIPE SUPPLIED WITH WATER HEATER MUST BE USED FOR VENT CONNECTION

NOTE: CPVC VENT PIPE AND VENT FITTINGS MUST BE USED IN CLOSET AND ALCOVE INSTALLATIONS.

VENT

AIR

Figure 3-5 Near Water Heater Venting Models 150 - 199

4” CPVC PIPE SUPPLIED WITH WATER HEATER MUST BE USED FOR VENT CONNECTION

NOTE: CPVC VENT PIPE AND VENT FITTINGS MUST BE USED IN CLOSET AND ALCOVE INSTALLATIONS.

VENT

AIR

Figure 3-6 Near Water Heater Venting Models 285 - 399

The Armor water heater uses model specific combustion air intake and vent piping sizes as detailed in Table 3B below.

Model Air Intake Vent

150 - 199 3 inches 3 inches 285 - 500 4 inches 4 inches

Table 3B Air Intake/Vent Piping Sizes

Increasing or decreasing combustion air or vent piping is not authorized.

NOTICE

Figure 3-7 Near Water Heater Venting Model 500

Air inlet pipe materials:

The air inlet pipe(s) must be sealed. Choose acceptable combustion air inlet pipe materials from the following list:

PVC, CPVC or ABS Dryer Vent or Sealed Flexible Duct (not recommended for rooftop air inlet) Galvanized steel vent pipe with joints and seams sealed as specified in this section. Type “B” double-wall vent with joints and seams sealed as specified in this section.

*Plastic pipe may require an adapter (not provided) to transition between the air inlet connection on the appliance and the plastic air inlet pipe.

AIR

VENT

4" CPVC PIPE SUPPLIED WITH WATER HEATER MUST BE USED FOR VENT CONNECTION

NOTE: CPVC VENT PIPE AND VENT FITTINGS MUST BE USED IN CLOSET AND ALCOVE INSTALLATIONS.

Installation & Operation Manual

3 General venting (continued)

Vent, air piping and termination:

The Armor water heater vent and air piping can be installed through the roof or through a sidewall. Follow the procedures in this manual for the method chosen. Refer to the information in this manual to determine acceptable vent and air piping length.

Air contamination

Pool and laundry products and common household and hobby products often contain fluorine or chlorine compounds. When these chemicals pass through the water heater, they can form strong acids. The acid can eat through the water heater wall, causing serious damage and presenting a possible threat of flue gas spillage or appliance water leakage into the building.

Please read the information given in Table 1A, page 11, listing contaminants and areas likely to contain them. If contaminating chemicals will be present near the location of the water heater combustion air inlet, have your installer pipe the water heater combustion air and vent to another location, per this manual.

If the water heater combustion air inlet is located in a laundry room or pool facility, for example, these areas will always contain hazardous contaminants.

To prevent the potential of severe personal injury or death, check for areas and products listed in Table 1A, page 11 before installing the water heater or air inlet piping.

If contaminants are found, you MUST:

• Remove contaminants permanently. —OR—

• Relocate air inlet and vent terminations to other areas.

Removing from existing vent

Follow the instructions in Section 1, page 11 of this manual when removing a water heater from an existing vent system.

Vent and air piping

Vent and air system:

Installation must comply with local requirements and with the National Fuel Gas Code, ANSI Z223.1 for U.S. installations or CSA B149.1 for Canadian installations.

You must also install air piping from outside to the water heater air intake adapter. The resultant installation is direct vent (sealed combustion).

You may use any of the vent/air piping methods covered in this manual. Do not attempt to install the Armor water heater using any other means.

DO NOT mix components from different systems. The vent system could fail, causing leakage of flue products into the living space. Use only PVC or CPVC pipe and fittings, with primer and cement specifically designed for the material used.

NOTICE

 WARNING

Model Kit Number

Equivalent Vent

Length

80 - 210 CVK3003 3 feet

285 CVK3007 3 feet

399 CVK3007 5 feet

500 CVK3007 30 feet

Table 3C Equivalent Vent Lengths

The appliance output rating will reduce by up to 1.5% for each 25 feet of vent length.

NOTICE

Minimum / Maximum allowable combustion air and vent piping lengths are as follows:

Combustion Air = 12 equivalent feet minimum / 100 equivalent feet maximum

Ve n t = 12 equivalent feet minimum / 100 equivalent feet maximum

When determining equivalent combustion air and vent length, add 5 feet for each 90° elbow and 3 feet for each 45° elbow.

EXAMPLE: 20 feet of PVC pipe + (4) 90° elbows + (2) 45° elbows + (1) concentric vent kit (CVK3003) = 49 equivalent feet of piping.

Installation & Operation Manual

4 Sidewall direct venting

Vent/air termination – sidewall

Follow instructions below when determining vent location to avoid possibility of severe personal injury, death, or substantial property damage.

A gas vent extending through an exterior wall shall not terminate adjacent to a wall or below building extensions such as eaves, parapets, balconies, or decks. Failure to comply could result in severe personal injury, death, or substantial property damage.

Installation must comply with local requirements and with the National Fuel Gas Code, ANSI Z223.1 for U.S. installations or CSA B149.1 for Canadian installations.

 WARNING

NOTICE

 WARNING

Do not connect any other appliance to the vent pipe or multiple water heaters to a common vent pipe. Failure to comply could result in severe personal injury, death, or substantial property damage.

Determine location

Locate the vent/air terminations using the following guidelines:

1. The total length of piping for vent or air must not exceed the limits given in the General Venting Section on page 17 of this manual.

2. You must consider the surroundings when terminating the

vent and air: a. Position the vent termination where vapors will

not damage nearby shrubs, plants or air conditioning equipment or be objectionable.

b. The flue products will form a noticeable plume as

they condense in cold air. Avoid areas where the plume could obstruct window views.

c. Prevailing winds could cause freezing of

condensate and water/ice buildup where flue products impinge on building surfaces or plants.

d. Avoid possibility of accidental contact of flue

products with people or pets.

e. Do not locate the terminations where wind eddies

could affect performance or cause recirculation, such as inside building corners, near adjacent buildings or surfaces, window wells, stairwells, alcoves, courtyards, or other recessed areas.

 WARNING

Sidewall vent and air inlet terminations must terminate in the same pressure zone.

f. Do not terminate above any door or window.

Condensate can freeze, causing ice formations.

g. Locate or guard vent to prevent condensate damage

to exterior finishes.

Do not exceed the maximum lengths of the outside vent piping shown in FIG. 4-1B. Excessive length exposed to the outside could cause freezing of condensate in the vent pipe, resulting in potential water heater shutdown.

Figure 4-1B Alternate Sidewall Termination of Air and Vent w/Field Supplied Fittings

 WARNING

If using the alternate sidewall termination:

3. The air piping must terminate in a down-turned elbow as shown in FIG. 4-1B. This arrangement avoids recirculation

of flue products into the combustion air stream.

4. The vent piping must terminate in an elbow pointed outward or away from the air inlet, as shown in FIG. 4-1B.

Figure 4-1A Sidewall Termination of Air and Vent

Model Kit Number Vent Size

150 - 199 KIT30045 3 inch vent

285 - 500 KIT30046 4 inch vent

Table 4A Sidewall Vent Kits

TO BOILER INTAKE AIR

CONNECTION

FROM BOILER

VENT PIPE

CONNECTION

POSSIBLE ORIENTATIONS

VENT / AIR

TERMINATION

GRADE OR

SNOW LINE

12"

MIN

TO OVERHANG

12"

MIN

FROM BOILER

VENT PIPE

CONNECTION

TO BOILER INTAKE AIR

CONNECTION

12” MIN

15” MAX

TERMINATION

PLATE

12”

BIRD

SCREEN

GRADE OR

SNOW LINE

MIN

BIRD SCREEN

Installation & Operation Manual

Vent/air termination – sidewall

4 Sidewall direct venting (continued)

5. Maintain clearances as shown in FIG.’s 4-1A thru 4-3B, pages 18 and 19. Also maintain the following: a. Vent must terminate:

• At least 6 feet from adjacent walls.

• No closer than 12 inches below roof overhang.

• At least 7 feet above any public walkway.

• At least 3 feet above any forced air intake within 10 feet.

• No closer than 12 inches below or horizontally from any door or window or any other gravity air inlet.

b. Air inlet must terminate at least 12 inches above

grade or snow line; at least 12 inches below the vent termination; and the vent pipe must not extend more than 24 inches vertically outside the building as shown in FIG. 4-1B.

c. Do not terminate closer than 4 feet horizontally

from any electric meter, gas meter, regulator, relief valve, or other equipment. Never terminate above or below any of these within 4 feet horizontally.

6. Locate terminations so they are not likely to be damaged by foreign objects, such as stones or balls, or subject to buildup of leaves or sediment.

Figure 4-1C Alternate Venting Arrangement (if Space Allows) w/Field Supplied Fittings

VENT / AIR

TERMINATION

12"

MIN.

12"

MIN.

12"

MIN.

Figure 4-2A Clearance to Gravity Air Inlets

Figure 4-2B Alternate Clearance to Gravity Air Inlets

w/Field Supplied Fittings

FORCED AIR

INLET

VENT / AIR

TERMINATION

7' MIN. ABOVE ANY

PUBLIC WALKWAY

IF LESS

THAN 10’

36"

MIN.

Figure 4-3A Clearance to Forced Air Inlets

Figure 4-3B Alternate Clearance to Forced Air Inlets

w/Field Supplied Fittings

TO BOILER INTAKE AIR

CONNECTION

FROM BOILER

VENT PIPE

CONNECTION

BIRD

SCREEN

ALTERNATE VENTING ARRANGEMENT

(IF SPACE PERMITS)

COUPLING

12” MIN

15” MAX

BIRD SCREEN

12”

MIN

Installation & Operation Manual

4 Sidewall direct venting

Termination and fittings

1. The air termination coupling must be oriented at least 12 inches above grade or snow line as shown in FIG. 4-1A, page 18.

2. Maintain the required dimensions of the finished termination piping as shown in FIG. 4-1A, page 18.

3. If using the alternate sidewall termination do not extend exposed vent pipe outside of the building more than what is shown in this document. Condensate could freeze and block vent pipe.

4. PVC/CPVC terminations are designed to accommodate any wall thickness of standard constructions per the directions found in this manual.

Prepare wall penetrations (Alternate Field Supplied Option)

1. Air pipe penetration: a. Cut a hole for the air pipe. Size the air pipe hole as

close as desired to the air pipe outside diameter.

2. Vent pipe penetration: a. Cut a hole for the vent pipe. For either combustible

or noncombustible construction, size the vent pipe hole with at least a 1/2 inch clearance around the vent pipe outer diameter:

• 4½ inch hole for 3 inch vent pipe

• 5½ inch hole for 4 inch vent pipe

b. Insert a galvanized metal thimble in the vent pipe

hole as shown in FIG. 4-4B.

3. Use a sidewall termination plate as a template for correct

location of hole centers.

4. Follow all local codes for isolation of vent pipe when passing

through floors or walls.

5. Seal exterior openings thoroughly with exterior caulk.

Figure 4-4A Sidewall Termination Assembly

Figure 4-4B Alternate Sidewall Termination Assembly

w/Field Supplied Fittings

All vent pipes and air inlets must terminate at the same height to avoid possibility of severe personal injury, death, or substantial property damage.

Multiple vent/air terminations

1. When terminating multiple Armor water heaters terminate each vent/air connection as described in this manual (FIG. 4-5A).

2. Place wall penetrations to obtain minimum clearance of 12 inches between edge of air inlet and adjacent vent outlet, as shown in FIG. 4-5A for U.S. installations. For Canadian installations, provide clearances required by CSA B149.1 Installation Code.

3. The air inlet of a Armor water heater is part of a direct vent connection. It is not classified as a forced air intake with regard to spacing from adjacent water heater vents.

 WARNING

12" MIN. BETWEEN EDGE OF AIR

INLET AND ADJACENT VENT OUTLET

VENT / AIR

TERMINATION

VENT

AIR

Figure 4-5A Multiple Vent Terminations (must also comply with Figure 4-1A)

Prepare wall penetrations

1. Use the factory supplied wall plate as a template to locate the vent and air intake holes and mounting holes. Air pipe penetration: a. Cut a hole for the air pipe. Size the air pipe hole as

close as desired to the air pipe outside diameter. Vent pipe penetration: a. Cut a hole for the vent pipe. For either combustible or

noncombustible construction, size the vent pipe hole

with at least a 1/2 inch clearance around the vent pipe

outer diameter:

• 4½ inch hole for 3 inch vent pipe

• 5½ inch hole for 4 inch vent pipe Drill 3/16" diameter holes for inserting the plastic anchors into the wall.

2. Install the vent and air intake piping through the wall into the vent plate openings. Seal all gaps between the pipes and wall. Use RTV silicone sealant to seal the air pipe. Use the cement/primer listed in Table 3A on page 15 to seal the vent pipe.

3. Mount and secure the vent plate to the wall using stainless steel screws. Seal around the plate to the wall assuring no air gaps.

4. Assemble the vent cap to the vent plate (see FIG. 4-4A). Insert the stainless steel screws into the vent cap screw hole openings and securely attach the vent cap to the vent plate.

5. Seal all wall cavities.

AIR PIPING

VENT PIPING

WALL PLATE

GALVANIZED

THIMBLE

VENT PLATE

VENT CAP

AIR PIPING

VENT PIPING

GALVANIZED

THIMBLE

SIDEWALL

TERMINATION PLATE

ELBOW

BIRD SCREEN

ELBOW

BIRD SCREEN

+ 44 hidden pages

Lochinvar 150 - 500, Armor AWN150PM, Armor AWN199PM, Armor AWN285PM, Armor AWN399PM Operation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual