Lochinvar ARMOR 151 - 801 User Manual

0 (0)
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
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 SW ITCH
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 PAN EL
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
1 Date and Time 14 Yes Yes Yes Yes
2 Software Version (read only) 14 No No Ye s No
3 Temperature Units (ºC/ºF) 14 Yes Yes Yes Yes
4 DHW Night Setback Offset 14 No No Ye s Yes
5 DHW Night Setback On Times 14 No No Ye s Yes
6 DHW Night Setback Off Times 14 No No Ye s Yes
7 Display Timeout 14 No No Ye s Yes
B
1 Reset Last 10 Errors 15 No No Ye s Yes
C
1 Service Mode Delay 15 No No Ye s Yes
D
1 Tank Set Point 15 Yes Yes Yes Yes
2 Tank Set Point Offset 15 Yes Yes Yes Yes
3 Tank Set Point Differential 15 No No Ye s Yes
4 Tank Minimum Set Point 15 No No Ye s Yes
5 Tank Maximum Set Point 15 No No Ye s Yes
E
1 Anti-Cycling Time 15 No No Ye s Yes
2 Anti-Cycling Override Differential 15 No No Ye s Yes
GENERAL
DATA
LOGGING
FUNCTIONS
DHW SETTINGS
ANTI-
CYCLING
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