Lochinvar Armor 150 - 500 User Manual

Service 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 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.

AW-SER Rev E

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

Viewable and Changeable Control Parameters . . . . . . . 13-15

2. MAINTENANCE

Maintenance and Annual Startup . . . . . . . . . . . . . . . . . . 16-20

3. TROUBLESHOOTING

Before Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Check Control Module Fuses . . . . . . . . . . . . . . . . . . . . . 21

Table 3A - Troubleshooting Chart - No Display . . . . . . . . 22

Checking Temperature Sensors . . . . . . . . . . . . . . . . . . . 23

Table 3D - Troubleshooting Chart - Noisy System . . . . . 24

Table 3E - Troubleshooting Chart - Fault Messages . . . . 25-31

Combustion Analysis Procedure . . . . . . . . . . . . . . . . . . . 32

Table 3F - Troubleshooting Chart - Combustion Levels . 32

Table 3G - Flue Products . . . . . . . . . . . . . . . . . . . . . . . . . 32

Gas Valve Adjustment Procedure . . . . . . . . . . . . . . . . . . 33

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.

Handling ceramic fiber materials

REMOVAL OF COMBUSTION CHAMBER LINING

The combustion chamber door insulation in this product 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 inhaled in the form of quartz or cristobalite from occupational sources is carcinogenic to humans (Group

1).”:

 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.

Service Manual

What is in this manual?

Service

Near water heater piping

• Typical system components

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

• C: Data Logging

• D: Functions

• E: WHR Settings

• H: Control Modes

• I: Circulation Pumps

• J: 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 expansion tank

• 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

The Armor water heater display

1 Service

Service Manual

Control inputs

GAS PRESSURE SWITCH

DHW THERMOSTAT

FLOW SWITCH

TANK SENSOR

SEQUENCER / BUILDING

MANAGEMENT SYSTEM

LOW WATER CUTOFF

INLET TEMPERATURE

SENSOR

OUTLET TEMPERATURE

SENSOR

FLUE GAS SENSOR

LOW VOLTAGE

CONNECTION

BOARD

AIR PRESSURE SWITCH

HIGH LIMIT SENSOR

FLAME SENSOR

BLOCKED DRAIN SWITCH

DISPLAY PANEL

PC INTERFACE

SMART SYSTEM

CONTROL BOAR

Service Manual

LOW VOLTAGE

CONNECTION

BOARD

SMART SYSTEM

CONTROL BOARD

ALARM BELL

AUX. DEVICE RELAY

RUNTIME CONTACTS

SEQUENCER / BUILDING

MANAGEMENT SYSTEM

DHW PUMP

IGNITER

BLOWER

GAS VALVE

DI SP LAY PAN EL

PC INTERFACE

Control outputs

1 Service (continued)

1 Service

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 1 shows control module normal sequences of operation for water heating operation.

Access modes

User

The user can adjust water heating set point using the UP and DOWN buttons at any time during normal operation. By entering the USER code (0704), the user can also change temperature units, time and date, and night setback settings. In user mode, the following parameters can be viewed but not changed: water heater model number; software version; total operating hours, and total cycles.

Installer

Most parameters are available only to the installer, accessible only by entering the installer access code (5309).

Saving parameters

To save parameters:

Press the ENTER/RESET button.

To keep parameter settings only for a current operating cycle:

Press the MENU/EXIT button 1 time to return to the parameter listings; press again to return to the menu listings.

Service Manual

Sequence of operation

Table 1A Sequence of operation

OPERATION DISPLAY

1. Upon a call for heat, the control turns on the water heater pump.

WHR: Standby OUT: 123.8F(129)

2. The control connects 120 VAC to the blower. The blower does not run at this time.

• If the unit is equipped with a flow switch, it must close before the

control powers up the blower.

• The manual reset high limit must be closed before the control

powers up the blower.

• If the unit is equipped with a solenoid valve and/or a vent

valve, they will be energized along with the blower.

• If the unit is equipped with a gas pressure switch, it must close

at this time.

• If there is an auxiliary device connected to the unit, the unit

will then provide 24 VAC to its enable relay. If the auxiliary device has a proving switch, it must close before the sequence continues.

WHR: Standby OUT: 123.8F(129)

3. The control then starts a 10 second prepurge cycle.

WHR: PREPURGE OUT: 123.9F(129)

4. Once the prepurge cycle is complete, and the blocked drain switch is closed, the control starts the 5 second trial for ignition by sending spark voltage to the spark electrode and opening the gas valve.

WHR: IGNITION OUT: 123.9F(129)

5. If the control does not detect flame by the end of the trial for ignition, the control performs a 10 second postpurge, another prepurge and tries to light the burner again. If the burner does not light after 4 trials (1 trial on the 500 model), the control locks out for 1 hour and then tries another set of 4 trials, except on the 500 model which is manual reset lockout.

WHR: POSTPURGE, PREPURGE OUT: 123.9F(129)

6. If the control detects a flame before the trial for ignition ends, it begins to modulate the burner in order to maintain the set point.

WHR: WHR 20% RATE OUT: 124.8F(129)

7. Once the call for heat is satisfied, the control will turn off the burner. The blower will remain on for the 10 second postpurge cycle. The water heater pump will continue to run for its pump delay time, then turn off.

WHR: POSTPURGE

OUT: 127.4F(129)

8. Water heater pump off.

WHR: Standby

OUT: 124.7F(129)

1 Service (continued)

1 Service

Service Manual

Display panel menu access

Table 1B Use this procedure to access menus from the display panel

DISPLAYBUTTON OPERATION

Enter Menu Code: 0000

Hold for 5 seconds -- display will change Press 9 times to change last digit

in readout to "9" Press 2 times to move to the second

digit Press 3 times to change second digit

in readout to "3"

MENU/EXIT

REVIOUS

Enter Menu Code:

000 9

Enter Menu Code:

009 0

Enter Menu Code:

009 3

PREVIOU

Press 1 time to change to the first digit

Enter Menu Code:

309 0

Press 5 times to change first digit in readout to "5"

Enter Menu Code:

309 5

Enter Menu Code: INSTALLER CODE

Press to enter the code

ENTER/RES

>A General B N/A

After 2 seconds, display shows menus (press ENTER/RESET to select a menu)

flashing

>C Data Log D Functions

Press 1 time to toggle menu listing

DOW

>E WHR Settings F N/A

Press 2 times to toggle menu listing

DOW

>G Anti-cycling H Control Modes

Press 1 time to toggle menu listing

DOW

>I Circ. Pumps

J Service Noti.

Press 2 times to toggle menu listing

DOW

If the code is entered incorrectly, the display will return to its previous mode. You will have to start over at step 1 to enter the code.

COMMENTS

Digit shown underlined at left will flash

The words, will flash while displayed

"INSTALLER CODE"

The caret symbol, ">" highlights the selectable line

The menu toggles to the next two menu options

If you enter a digit incorrectly, you can move to the digit by using the NEXT and PREVIOUS buttons as needed until the digit you want is flashing. Then use UP and/or DOWN buttons to change the value.

To select a highlighted menu, press the ENTER/RESET button one time. The display will change to the first parameter under that menu, with the first characters flashing.

WHR:OFF OUT:125˚F

Press 1 time in normal operation

ENTER/RES

Water heater turns off (this ensures uninterrupted programming)

Service Manual

Display panel parameter access

Table 1C This is a typical example of accessing a parameter, shown for parameter H3, cascade address

1 Service (continued)

DISPLAYBUTTON OPERATION

This example shows how to access parameter H3, cascade address. The first display shown is at the beginning of the menu listings, after entering the installer access code.

DOW

ENTER/RES

(

DOWN

ENTER/RES

Beginning of menu listings.

Press 1 time to toggle menu listing

Press 2 times to toggle menu listing

Press 1 time to toggle menu listing

Press 1 time to select second listing

Press 1 time to list parameters

Press 1 time to select next parameter

Press 1 time to show parameter value

Press 1 time to change value

)

Press 1 time to save new value

>A General B N/A

>C Data Log D Functions

>E WHR Settings F N/A

>G N/A H Control Modes

G Anti-Cycling >H Control Modes

H2 Contrl Source

H3 Cascade Addr

Cascade Addr

Member 0001

Cascade Addr

Member 0002

H3 Cascade Addr

COMMENTS

The caret symbol, ">" highlights the selectable line

The menu toggles to the next two menu options

will flash

will stop flashing; parameter value will appear

Parameter will increase or decrease,

depending on button pressed

will flash

ENTER/RES

Press 1 time to return to main menu Press 1 time to return to normal

operation

>A General

B N/A

WHR:Pre-Purge OUT:123.7˚F

This display example assumes a call for water heating is present

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