Lochinvar ArmorX2 1, ArmorX2 1.5, ArmorX2 1.3 User Manual

AWX2-SER Rev A

Service Manual

Models: 1.0, 1.3, and 1.5

 WARNING

Save this manual for future reference.

This manual must only be used by a qualified heating installer / service technician. Read all instructions, including this manual and the Armor X2 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.

Contents

CONTENTS ........................................................................ 2

Hazard Definitions .............................................................. 2

PLEASE READ BEFORE PROCEEDING ......................... 2

Handling Ceramic Fiber Materials ...................................... 3

When servicing water heater ........................................ 3

Water heater operation ................................................ 3

Heater water ................................................................. 3

Freeze protection fluids ................................................ 3

WHAT IS IN THIS MANUAL .............................................. 4

1. SERVICE

The Armor X2 Water Heater Display ................................. 5

Control Inputs ............................................................... 6

Control Outputs ............................................................. 7

General Operation ........................................................ 8

Sequence of Operation ...................................................... 9

Parameter Table.......................................................... 10-11

Viewable and Changeable Control Parameters .......... 12-31

2. MAINTENANCE

Maintenance and Annual Startup ................................ 32-36

3. TROUBLESHOOTING

Alarm Screen.................................................................... 37

Before Troubleshooting .................................................... 38

Check Control Module Fuses .......................................... 38

Table 3A - Troubleshooting Chart - No Display ......... 39

Checking Temperature Sensors ...................................... 40

Table 3D - Troubleshooting Chart - Noisy System ..... 41

Table 3E - Troubleshooting Chart - Fault Messages 42-48

Combustion Analysis Procedure ...................................... 49

Table 3F - Troubleshooting Chart - Combustion Levels 49

Table 3G - Flue Products ........................................... 49

Gas Valve Adjustment Procedure .................................... 50

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

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.

Please read before proceeding

 WARNING

Installer – Read all instructions, including this manual and the Armor X2 Installation and Operation Manual, before installing. Perform steps in the order given.

User – This manual is for use only by a qualified heating installer/service technician.

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.

NOTICE

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 X2 Installation and Operation Manual).

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

Please read before proceeding

Service Manual

 WARNING

Installer – Read all instructions, including this manual and the Armor X2 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.

Handling ceramic fiber materials

REMOVAL OF COMBUSTION CHAMBER LINING

 WARNING

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.

NOTICE

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 X2 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.

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.

• 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.

What is in this manual?

Service Manual

Service

The Armor X2 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 X2 water heater operation

• Setup

• Service / Setup

• Setpoint

• Night Setback

• Cascade

• Pumps

• BMS

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

The Armor X2 display

Service Manual

1 Service

Control inputs

LOW VOLTAGE

CONNECTION

BOARD

SEQUENCER / BUILDING

MANAGEMENT SYSTEM

Service Manual

SECONDARY

SMART CONTROL

MODULE

PRIMARY

SMART CONTROL

MODULE

HW TANK SENSOR

ENABLE

HEAT EXCHANGER SWITCH

TOUCH DISPLAY

O-TEMP

BLOCKED DRAIN SWITCH

FLOW SWITCH

TOUCH PANEL

INTERFACE

HEAT EXCHANGER SWITCH

O-TEMP

PRIMARY/SECONDARY INLET

TEMPERATURE SENSOR

PRIMARY/SECONDARY OUTLET

TEMPERATURE SENSOR

FLOW SW ITCH

PRIMARY/SECONDARY

FLUE GAS SENSOR

PRIMARY/SECONDARY

HIGH LIMIT SENSOR

PRIMARY/SECONDARY

FLAME SENSOR

PC INTERFACE

MODBUS COMMUNICATION

BOARD

IMG00166

1 Service (continued)

Control outputs

Service Manual

SECONDARY

LOW VOLTAGE

CONNECTION

BOARD

ALARM BELL

RUN TIME CONTACTS

PRIMARY

SMART TOUCH

CONTROL MODULE

SMART TOUCH

CONTROL MODUL

SEQUENCER / BUILDING

MANAGEMENT SYSTEM

TOUCH DISPLAY

PC INTERFACE

HEAT EXCHANGER 1 / HEAT EXCHANGER 2 HW PUMP

TOUCH PANEL

INTERFACE

IGNITOR

BLOWER

GAS VALVE

1 Service

General Operation

Service Manual

How the water heater operates

The Armor X2 uses two (2) advanced stainless steel heat exchangers and two (2) electronic control modules that allow fully condensing operation. The blowers pull in gas and air and push flue products out of the water heater through the heat exchangers and flue piping. The control modules regulate blower speeds to control total water heater firing rate. The gas valves sense the amount of air flowing into the water heater and allow only the right amount of gas to flow.

Sequence of operation

Table 1A shows control module normal sequences of operation for each individual control module. Additionally, the control modules are programmed to synchronize their combined modulation rates in order to maximize total water heater efficiency.

Access modes

User

The user can view all of the settings on the LCD screen. By entering the user password (0704), the user can adjust the User Set Point, Outdoor Shutdown, Night Setback, Boost, HW Water Heater Output Set Point, Backlight Time, and Backlight Brightness settings.

Installer

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

Service Manual

1 Service (continued)

Sequence of operation

Table 1A Sequence of operation

Note: This unit is equipped with two (2) independent, but synchronized combustion systems. One of the heat exchanger combustion systems will fire first. If the demand cannot be met by one (1) combustion system the same sequence of operation will be followed to bring the second heat exchanger combustion system online.

Upon a call for heat, the control turns on the appropriate pumps.

The control confirms that the flow switch contacts are closed.

The control starts the blower and closes the louver contacts to begin the Pre-Purge cycle.

The control confirms that the blower comes up to the desired speed, the flap valve opens, and the air pressure switch,

gas pressure switch (optional), louver proving switch (optional), and blocked drain switch contacts close.

10.

11.

Once the Pre-Purge cycle is complete, the control lowers the blower speed, initiates sparking of the ignition electrode, and opens the gas valve.

After a short wait, the control stops sparking and checks for the presence of flame current through the spark and flame sense electrodes.

If the control does not detect flame current, the control will try again. If no flame current is detected on the second try, the control will lockout indefinitely until the RESET button on the touch screen LCD is pressed.

If the control detects flame current, the control will hold the blower speed constant for a few seconds to allow the flame to stabilize, then begin modulating the firing rate in order to maintain the controlling sensor to the desired set point temperature.

If the first heat exchanger in the water heater is unable to maintain the desired set point temperature, the second heat exchanger in the water heater will be started, using much of the same sequences as described above. Once both heat exchangers are firing, the controls will work in synchronization to maintain the desired set point temperature. If the heat load should decrease sufficiently, the second heat exchanger will be shut down, much like the sequences described below.

Once a call for heat is satisified, the control will turn off the gas valve and begin the Post-Purge cycle. The pumps that are running will begin their respective Pump Delay cycles.

At the end of the Post-Purge cycle, the louver contacts will open.

12.

13.

The control verifies that the blower stops running and the flap valve closes.

At the end of the Pump Delay cycle(s), the pump(s) will be turned off.

Service Manual

1 Service

Parameter table

Table 1B This table lists the parameters and where to access them

MENU DESCRIPTION

Service/Setup 17 Yes Yes Yes Yes Night Setback 17 Yes Yes Yes Yes

SETUP

Set points 17 Yes Yes Yes Yes Cascade 17 Yes Yes Yes Yes BMS 17 Yes Yes Yes Yes

Demand Conf 18 Yes No Yes No Serv Not Time 18 No No Yes Yes Serv Not Run H 18 No No Yes Yes Serv Not Cycl 18 No No Yes Yes Max Serv T 19 Yes No Yes No

Temp Unit 19 No No Yes Yes

User Passwd 19 No No Yes Yes

PARAMETERS

SERVICE / SETUP

LCD Backlight 19 No No Yes Yes

LCD Bright 19 No No Yes Yes

SEE

PAGE

USER ACCESS INSTALLER ACCESS

DISPLAY MODIFY DISPLAY MODIFY

SET POINT

PARAMETERS

HW Pump D 19 No No Yes Yes

Tank setp 20 No No Yes Yes

Tank on df 20 No No Yes Yes

Tank off df 20 Yes Yes Yes Yes

NSB setp 20 No No Yes Yes

Drop in Inlet Anti-C t 20 No No Yes Yes

Tank Off Diff 20 Yes Yes Yes Yes

20 No No Yes Yes

Service Manual

1 Service (continued)

Table 1B (continued from previous page) This table lists the parameters and where to access them

Date and time 21 Yes Yes Yes Yes

NIGHT

SETBACK

CASCADE

BMS

On Timer and Off Timer 21 No No Yes Yes

Casc Address 22 Yes Yes Yes Yes Casc off df 22 No No Yes Yes Casc off/on df 22 No No Yes Yes Max Outl temp 22 No No Yes Yes

BMS Type 23 No No Yes Yes

ModBus Timeout 23 No No Yes Yes

BMS Setp min V 23 No No Yes Yes

BMS Setp max V 23 No No Yes Yes

BMS V min Setp 23 No No Yes Yes

BMS V max Setp 23 No No Yes Yes

BMS V Heat 23 No No Yes Yes

Dropin BMS End 23 No No Yes Yes

BMS mod@minV 24 No No Yes Yes

BMS mod@maxV 24 No No Yes Yes

BMS V @min mod 24 No No Yes Yes

BMS V @max mod 24 No No Yes Yes

Service Manual

1 Service

Viewable and changeable control parameters

Status Screen:

When the ON/OFF switch is turned to the ON position, the first screen visible on the LCD display will be the Status Screen. This screen displays the current status of the Armor X2 water heater. The following items can be viewed or interacted with on the Status Screen:

On/Off button - Pressing this button allows the water heater to be placed in either Manual Shutdown Mode or Standby Mode.

Status - This line shows the current operating status of the Armor X2 water heater. Displayed items are as follows:

• Manual Shutdown - The water heater will not respond to a hot water call.

• Standby - The water heater has not received a hot water call.

• HW Storage - The water heater has received a hot water call.

• HW Pump Delay - The water heater has satisfied a hot water call and the hot water pumps are running for a fixed time to remove any residual heat.

• BMS - The water heater has received a call for heat from a 0-10 VDC BMS control.

• Service Set Point Met - While in Service Mode, the water temperature at either the outlet sensor or the system sensor has exceeded 185°F.

• Anti-Cycle Delay - The water heater has satisfied a call for heat, but has received another call for heat before the anti cycling time parameter has elapsed.

• Cascade ComError - A communication error has occurred between the Control Module 1 and Control Module 2 or between the Leader and Member water heaters.

1 Service (continued)

Service Manual

Configuration - This line shows the current configuration of the two control modules inside the unit.

Outlet Water Temperature - This is a calculated temperature based on the readings of the outlet temperatures of the two (2) heat exchangers.

Inlet Water Temperature - This is a calculated temperature based on the inlet temperature readings from the two (2) heat exchangers.

Hot Water Tank Temperature - This is the temperature as measured by the tank sensor in the hot water storage tank.

Time - The time is displayed in the upper right-hand corner of the display. It is displayed in a 24 hour format. Reference the Night Setback parameters on page 21 for information regarding adjusting the date and time.

Details button - Pressing this button brings up the Details Screen. This screen shows the status of the various safeties, inputs, and outputs to each control module. Reference the Details Screen section on page 14 for more information regarding this screen.

Main button - Pressing this button brings up the Main Screen. From this screen navigation to eight (8) other screens is possible. Reference the Main Screen section on page 16 of this manual for more information regarding this screen.

1 Service

Details Screen:

Service Manual

The Details Screen is accessed by pressing the DETAIL button on the Status Screen. This screen shows the status of the various safeties, inputs and outputs to each control module. Selection of the control module to be viewed is accomplished by pressing the SELECT button. The control module being displayed is shown in the module box.

Displayed items are as follows:

• HW Thermostat - Is ON when a Hot Water call has been received from a tank thermostat. Is OFF when a Hot Water call has not been received from a tank thermostat.

• Gas Pressure Switches - Is ON when the high and low gas pressure switches are closed. If OFF when either the high or low gas pressure switches are open.

• Louver Proving Switch - Is ON when a remote proving safety switch is closed. Is OFF when a remote proving safety switch is open.

• Manual Reset High Limit - Is ON when the manual reset high limit is closed. Is OFF when the manual reset high limit is open.

• Air Pressure Switch - Is ON when the combustion air blower is energized and the flap valve switch is closed. Is OFF when the flap valve switch is open.

• Flow Switch / Low Water Cutoff - Is ON when the low water cutoff contacts are closed or if an optional flow switch is used and it is closed as well. Is OFF when the low water cutoff contacts are open or if an optional flow switch is open.

• Blocked Drain Switch - Is ON when the blocked drain switch on the condensate trap is closed. Is OFF when the blocked drain switch on the condensate trap is open.

• Auto Reset High Limit - An auto reset high limit is not used in the standard configuration of the Armor X2 water heater. If OFF is shown then a wiring problem exists.

• HW Pump - Is ON when a Hot Water Generation call has been received from a tank thermostat or a tank sensor and the hot water generation pump is energized. Is OFF when the hot water generation pump is de-energized.

• Gas Valve - Is ON when the gas valve is energized. Is OFF when the gas valve is de-energized.

• Alarm - Is ON when a fault has been detected and the alarm contacts are closed. Is OFF when the alarm contacts are open.

• Blower Power - Is ON when the combustion air blower is energized. Is OFF when the combustion air blower is de energized.

• Run Time Contacts - Is ON when the burner is energized. Is OFF when the burner is de-energized.

• 0-10Vdc - Shows the voltage signal being delivered from a remote Building Management System (BMS).

1 Service (continued)

Service Manual

A blank message box is located on the Details Screen. This box will display various messages detailing the status of the control module. If a message is present in this box, the DETAILS button on the Status Screen will contain a yellow triangle with an exclamation mark (!) inside.

Displayed items are as follows:

• Delta T Shutdown - The temperature rise between the inlet and outlet temperatures has exceeded 35°F. Reference page 48 for more information regarding this shutdown.

• Outlet Temp Shutdown - The outlet temperature has exceeded 195°F. Reference page 48 for more information regarding this shutdown.

• Flue Temp Shutdown - The flue temperature has exceeded 240°F. Reference page 48 for more information regarding this shutdown.

• Voltage too Low - The 120 VAC input to the control has dropped below 80 VAC. Reference page 47 for more information regarding this fault message.

• Connect Tank Sensor - Tank sensor is not detected by Control Module 1. For proper operation of the Armor X2 water heater the tank sensor must be connected.

• Manual Shutdown - The water heater has been shutdown with the ON/OFF button on the Status Screen.

Time - The time is displayed in the upper right-hand corner of the display. It is displayed in a 24 hour format. Reference the night setback parameters on page 22 for information regarding adjusting the date and time.

Status button - Pressing this button displays the Status Screen. This screen shows the current status of the Armor X2 water heater. Reference pages 12 - 13 for more information regarding this screen.

Main button - Pressing this button displays the Main Screen. From this screen, navigation to eight (8) additional screens is possible. Refer to Main Screen on page 16 for more information regarding this screen.

1 Service

Main Screen:

Service Manual

The Main Screen allows navigation to eight (8) additional screens which are used to set temperatures, operating conditions, and monitor water heater operation. These screens are as follows:

• Setup - Allows access to five (5) other screens for the adjustment of the control parameters.

• Cascade - Shows the status of multiple heaters connected together in a cascade arrangement.

• Temps - Shows the temperatures measured by the individual sensors connected to the heater.

• Burners - Shows the status of the two (2) independent burner systems used in the heater.

• Building - Shows the information from a Building Integration System using Modbus Protocols.

• Graphs - Allows the selection of items to be graphed on a chart.

• History - Shows the operating and fault history of the two (2) control modules.

• Service Mode - Allows the installer to control the fan speed of the individual control modules for the purposes of combustion analysis. Service Mode will override all other heat demands, however, all safeties will continue to function.

Navigation to the Main Screen can be accomplished by pressing the MAIN button at the bottom of the page.

Reference pages 17 - 31 of this manual for more information regarding the eight (8) accessible screens.

Time - The time is displayed in the upper right-hand corner of the display. It is displayed in a 24 hour format. Reference the night setback parameters on page 21 for information regarding adjusting the date and time.

Status button - Pressing this button displays the Status Screen. This screen shows the current status of the Armor X2 water heater. Reference pages 12 - 13 for more information regarding this screen.

+ 36 hidden pages