Lochinvar ARMOR 151 - 801 User Manual

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 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.

AWII-SER Rev A

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.

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.

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

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

Service Manual

Control inputs

GAS PRESSURE SWITCH

DHW THERMOSTAT

FLOW SW ITCH

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

LOUVER PROVING SWITCH

FLAME SENSOR

BLOCKED DRAIN SWITCH

DISPLAY PANEL

PC INTERFACE

SMART SYSTEM

CONTROL BOARD

Service Manual

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

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

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

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

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

Service Manual

Parameter table

Table 1D This table lists SMART SYSTEM control module parameters and where to access them

Sub

Item

Description

See

Page

User Access Installer Access

Display Modify Display Modify

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

1 Reset Last 10 Errors 15 No No Ye s Yes

1 Service Mode Delay 15 No No Ye s Yes

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

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

+ 28 hidden pages