Lochinvar OAL151PM Installation Manual

 WARNING: 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

OAW-I-O Rev I

Outdoor Armor W a ter

Heater Installation &

Operation Manual

Models: 151 - 801

• 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

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 Outdoor 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.

Contents

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

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

THE OUTDOOR ARMOR WATER HEATER -- HOW IT

WORKS ........................................................................... 4-6

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

1. DETERMINE WATER HEATER LOCATION

Provide Clearances ............................................................ 9

Outdoor Vent / Air Intake Location ..................................... 9

Flooring and Foundation ................................................... 9

Prevent Combustion Air Contamination ............................. 9

Corrosive Contaminants and Sources ............................... 9

2. PREPARE WATER HEATER

Remove Water Heater from Wood Pallet ........................ 10

Gas Conversions ......................................................... 11-12

Leveling the Water Heater .......................................... 12

3. SYSTEM PIPING

System Water Piping Methods ......................................... 13

Flow Switch and Relief Valve Installation ................... 13-14

Flow Switch Adjustment ................................................... 14

Scalding ............................................................................ 14

Water Chemistry............................................................... 15

Piping Components .......................................................... 15

4. GAS CONNECTIONS

Connecting Gas Supply Piping ........................................ 21

Natural Gas ...................................................................... 22

Pipe Sizing for Natural Gas ........................................ 22

Natural Gas Supply Pressure Requirements ............. 22

Propane Gas .................................................................... 22

Pipe Sizing for Propane Gas ...................................... 22

Propane Supply Pressure Requirements ................... 22

Check Inlet Gas Supply ................................................... 23

Gas Pressure ................................................................... 24

Gas Valve Replacement .................................................. 24

5. FIELD WIRING

Line Voltage Connections ................................................ 25

Low Voltage Connections ................................................ 25

Wiring of the Cascade ...................................................... 27

6. CONDENSATE DISPOSAL

Condensate Drain ............................................................ 29

7. STARTUP ............................................................... 30-35

8. OPERATING INFORMATION

General ............................................................................. 36

Cascade ........................................................................... 38

Sequence of Operation .................................................... 39

Outdoor Armor Water Heater Control Module ................. 40

Status Display Screens ............................................... 41-43

9. MAINTENANCE

Maintenance & Annual Startup ................................... 44-48

10. DIAGRAMS

Ladder Diagram ............................................................... 49

Wiring Diagram................................................................. 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.

Outdoor Armor Water Heater Installation & Operation Manual

Please read before proceeding

 WARNING

NOTICE

 WARNING

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

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.

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

 WARNING

DO NOT install units in rooms or environments that contain corrosive contaminants (see Table 1B on page 9). Failure to comply could 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.

 WARNING

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 near the water heater.

• Do not touch any electric switch.

• Immediately call your gas supplier. 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.

Outdoor Armor Water Heater Installation & Operation Manual

The Outdoor 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. Combustion chamber 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 (limit rated - not shown)

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 (housed with the high limit sensor)

This sensor monitors water heater outlet water temperature.

8. Water heater inlet temperature sensor

This sensor monitors return water temperature. If the tank sensor is not connected, the control module will adjust 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 LCD display

The electronic display consists of 4 buttons, a navigation dial and a multiple line liquid crystal display.

11. 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.

12. Water outlet

NPT water connection that supplies hot water to the tank.

13. Water inlet

NPT water connection that returns water from the tank to the heat exchanger.

14. Gas connection pipe

Threaded pipe connection. This pipe should be connected to the incoming gas supply for the purpose of delivering gas to the water heater.

15. SMART SYSTEM Control Module

The SMART SYSTEM Control responds to internal and external signals and controls the blower, gas valve, and pumps to meet the demand.

16. Manual air vent

Designed to remove trapped air from the heat exchanger coils.

17. High voltage junction box

The junction box contains the connection points for the line voltage power and the pump.

18. Water heater drain port

Location from which the heat exchanger can be drained.

19. Low voltage connection board

The connection board is used to connect external low voltage devices.

20. Low voltage wiring connections (plugs)

Conduit connection points for the low voltage connection board.

21. Condensate drain connection

Connects the condensate drain line to a 1/2" PVC union.

22. Access cover - front (not shown)

Provides access to the gas train and the heat exchanger.

23. Ignition electrode

Provides direct spark for igniting the burner.

24. Flame inspection window

The quartz glass window provides a view of the burner surface and flame.

25. Gas shutoff valve

Manual valve used to isolate the gas valve from the gas supply.

26. High limit sensor (housed with the outlet temperature sensor)

Device that monitors the outlet water temperature. If the temperature exceeds its setting, the integrated control will break the control circuit, shutting the water heater down.

27. Relief valve

Protects the heat exchanger from over pressure and temperature conditions. The relief valve is set at 150 PSI / 210°F.

28. Flame sensor

Used by the control module to detect the presence of burner flame.

29. Line voltage wiring connections (plugs)

Conduit connection points for the high voltage junction box.

30. Top panel

Removable panel to gain access to the internal components.

31. Power switch

Turns 120 VAC ON/OFF to the water heater.

32. 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.

33. Air shroud (501 Model Only - not shown)

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

34. Air pressure switch

The air pressure switch detects blocked inlet or outlet conditions.

35. Pump relay (not shown)

The pump relay is used to control the circulation pump.

36. Transformer (not shown)

The transformer provides 24V power to the integrated control.

37. Gas shutoff switch (Models 151 - 286 Only - not shown)

An electrical switch designed to cut power to the gas valve to prevent releasing any gas.

38. Over-temp switch (Models 286 - 801) (located underneath vent cover - not shown)

An electrical switch designed to shut down water heater operation in the event the outer back of the heat exchanger, directly above the flue connection exceeds 604°F (318°C). This is a one time switch and could warrant a heat exchanger replacement. Check the integrity of the rear refractory at the back of the upper coil if the switch opens.

39. Vent / air cover

On Models 400 - 801 it functions as a vent cover only. Covers the over-temp switch and the flue collar with flue sensor.

40. Air intake

Provides combustion air to the appliance.

41. Air intake cover (Models 400 - 801 Only)

Provides protection from outdoor elements.

42. Flue pipe assembly

Factory supplied components for a complete venting system.

43. Burner door temperature switch (Models 286 - 801 Only)

An electrical switch designed to shut down water heater operation in the event the combustion chamber access cover exceeds 500°F (260°C). This switch may only be reset by a qualified service technician AFTER the underlying cause has been identified and corrected. Check the integrity of the front refractory on the inside of the combustion chamber access cover if the switch opens.

Outdoor Armor Water Heater Installation & Operation Manual

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

Models 151 - 200

Rear View - Models 151 - 200

Left Side (inside unit) - Models 151 - 200

IMG00360

Rear View - Model 286

Left Side (inside unit) - Model 286

Outdoor Armor Water Heater Installation & Operation Manual

The Outdoor Armor Water Heater - How it works...

Models 400 - 501

Rear View - Models 400 - 501

Models 601 - 801

IMG00396

Left Side (inside unit) - Models 400 - 501

Rear View - Models 601 - 801

IMG00288

IMG00289

Left Side (inside unit) - Models 601 - 801

Ratings

Outdoor Armor Water Heater Installation & Operation Manual

Model Number

Note: Change “N” to “L” for

L.P. gas models.

OAN151PM 30,000 - 150,000 1.3 1-1/4" 1/2"

OAN200PM 40,000 - 199,999 1.8 1-1/4" 1/2"

OAN286PM 57,000 - 285,000 2.5 2" 3/4" OAN400PM 80,000 - 399,999 3.4 2" 1" OAN501PM 100,000 - 500,000 3.9 2" 1" OAN601PM 120,000 - 600,000 3.9 2" 1" OAN701PM 140,000 - 700,000 4.4 2" 1" OAN801PM 160,000 - 800,000 4.9 2" 1"

NOTICE

Maximum allowed working pressure is located on the rating plate.

CSA

Input Modulation Btu/hr

(Note 2)

HLW

Water Content

Gallons

LOW LEAD CONTENT

Water

Connections

Gas

Connections

Notes:

1. Outdoor Armor water heaters are supplied with special gas venting materials. Use only the method of installation specified in the Outdoor Armor Installation and Operation Manual.

2. Standard outdoor Armor water heaters are equipped to operate from sea level to 4,500 feet only with no adjustments. The water heater will de-rate by 4% for each 1,000 feet above sea level up to 4,500 feet.

3. The manual reset high limit provided with the outdoor water heater is listed to UL353. The auto reset high limit is listed to ANSI Z21.87.

Outdoor Armor Water Heater Installation & Operation Manual

1 Determine water heater location

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.

NOTICE

 WARNING

CAUTION

 WARNING

Tabe 1A - Ambient Temperature

Model Kit Number

OK 151/211 OA 151/200

OK/OA 286 KIT30124

OK/OA

501 - 801

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

Outdoor models must be installed outdoors only and must use the outdoor vent kit assembly supplied by the manufacturer. Personal injury or product damage may result if any other cap is used or if an outdoor model is used indoors. All covers, doors and jacket panels must be properly installed to ensure proper operation and prevent a hazardous situation.

This product contains a condensate management and disposal system that may be subject to freezing if exposed to sustained temperatures below 32°F. Precautions should be taken to protect the condensate trap and drain lines during extended periods of outdoor temperatures below 32°F. Consult the manufacturer (and see Table 1A below) for an optional condensate trap kit recommended for areas which may experience temperatures below 32°F. Note: This condensate option is only available for Models OA 151 - 286 and

501 - 801. Model OA 400 is NOT suitable for installation in areas which may experience temperatures below 32°F.

Requirements

Minimum Allowable

Ambient Temperature

KIT30123

KIT30125

5°F (OK/OA 601 - 801)

5°F 5°F

10°F (OK/OA 501)

Before locating the water heater, check:

1. Check for nearby connection to:

• Water piping

• Gas supply piping

• Electrical power

2. - Keep venting areas free of obstructions.

- Keep area clean and free of combustible and flammable materials.

- To avoid a blocked air inlet or blocked flue condition, keep the outdoor air inlet and flue outlet clear of leaves, debris, etc.

CAUTION

 CAUTION

 WARNING

CAUTION

3. Check area around the water heater. Remove any combustible materials, gasoline and other flammable liquids.

Do not install outdoor models directly on the ground. You must install the outdoor unit on a concrete, brick, block or pressuretreated wood platform.

Do not locate unit so that high winds can deflect off of adjacent walls, buildings or shrubbery causing recirculation. Recirculation of flue products may cause operational problems, bad combustion or damage to controls. Locate unit at least 3 feet (0.91m) from any wall or vertical surface to prevent wind conditions from affecting performance.

The outdoor unit must not be installed in an area that is enclosed by walls or a fence that will block free wind movement around the unit. Free movement of wind around the outdoor unit is required to carry away the flue products and provide combustion air. The flue outlet/combustion air inlet of an outdoor unit must not be installed closer than 10 feet from an inside corner of an L-shaped structure. Walls or enclosed fencing may cause eddy currents which can recirculate the flue products into the combustion air inlet. Recirculation of flue products may cause operational problems, bad combustion or non-warrantable damage to controls.

- Do not install the outdoor unit under a deck.

- Do not install an outdoor unit in a well, stairwell, alcove, courtyard or other recessed area.

- Do not install outdoor units on stack frames. Failure to comply with the above could result in severe personal injury, death or substantial property damage.

- Do not install outdoor units in locations where rain from building runoff drains will spill onto the unit.

- Do not locate the outdoor unit so that water from sprinklers may spray directly onto it. Water may damage controls or other electrical components.

Outdoor Armor Water Heater Installation & Operation Manual

1 Determine water heater location (continued)

 WARNING

4. If a new water heater will replace an existing water heater, check for and correct system leaks causing oxygen corrosion or heat exchanger cracks from hard water deposits.

5. Check around the water heater for any potential air

contaminants that could risk corrosion to the water heater or the water heater combustion air supply (see Table 1B). Prevent combustion air contamination. Remove any of these contaminants from the water heater area.

 WARNING

Failure to keep the 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.

DO NOT install units in rooms or environments that contain corrosive contaminants (see Table 1B). Failure to comply could result in severe personal injury, death, or substantial property damage.

Provide clearances:

Clearances from combustible materials

1. Hot water pipes—at least 1/4" (6mm) from combustible

materials.

2. Vent pipes—minimum of 14" (356mm) from the rear and

0" on the right side from combustible materials.

Clearances for service access

1. If you do not provide the minimum clearances, it may

not be possible to service the water heater without removing it from the space.

Recommended service clearances:

Front - 30" (762mm) Top - 24" (610mm) Left side - 24" (610mm) Rear - 24" (610mm)

Outdoor vent / air intake location

 WARNING

To prevent recirculation of the flue products into the combustion air inlet, follow all instructions in this section. Flue gas condensate can condense on exterior walls or on the vent. Some discoloration to exterior building or unit surfaces can be expected. Adjacent brick or masonry surfaces should be protected with a rust resistant sheet metal plate.

Maintain a minimum of 24" (610mm) clearance to the side of the air inlet. Locate the outdoor vent termination at least 48" (1.22m) below and 48" (1.22m) horizontally from any window, door, walkway or gravity air intake. Locate outdoor unit at least 10 feet (3.05m) away from any forced air inlet. Multiple outdoor unit installations require 24" (.61m) clearance between each vent termination. Clearances around outdoor installations can change with time. Do not allow the growth of trees, shrubs or other plants to obstruct the proper operation of the outdoor vent system.

The flue products discharged from the flue outlet on the outdoor vent may be very hot. Avoid touching or other direct contact with the flue gases or the vent termination assembly. These components are hot and direct contact can result in burns.

Flooring and foundation

Flooring

The outdoor Armor water heater is approved for installation on combustible flooring.

 WARNING

Under no circumstances is the manufacturer to be held responsible for water damage in connection with this appliance, or any of its components. If flooding is possible, elevate the water heater sufficiently to prevent water from reaching the water heater.

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.

Prevent combustion air contamination

Do not install in locations that can allow contamination of combustion air. Refer to Table 1B for products and areas which may cause contaminated combustion air.

Table 1B Corrosive Contaminants and Sources

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

Outdoor Armor Water Heater Installation & Operation Manual

2 Prepare water heater

Remove water heater from wood pallet

1. After removing the outer shipping carton from the water heater, remove the installation kit.

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.

Figure 2-2 Install Flue Pipe Assembly - Models 151 - 601

NOTICE

Figure 2-1 Water heater Mounted on Shipping Pallet

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

Install flue pipe assembly - Models

151 - 601 (reference FIG. 2-2 for flue pipe assembly installation)

The outdoor water heater is shipped with all the necessary

vent components. All components must be installed prior to operation. Basic steps are listed below to guide you through the installation of the flue pipe assembly provided with the unit.

1. Locate all venting components from the installation kit and carton.

2. Before connecting the vent pipe sections or components, verify the gasket is seated evenly inside the groove in the female end of the elbow and flue adapter.

3. Remove the factory provided screws from the vent/air cover and use them to install the wall strap.

4. Insert the elbow into the flue adapter.

 CAUTION

5. Slide the flue pipe through the wall strap and insert it into the elbow.

6. Install the bird screen into the top of the vent.

Do not use grease or other lubricant on the vent seals. Only water may be used for this purpose. Grease or other lubricant can make the seal brittle or it can result in tears in the surface of the seal, this will result in flue gas leakage.

Install flue pipe assembly - Models

701 - 801 (reference FIG. 2-3 for flue pipe assembly installation)

The outdoor water heater is shipped with all the necessary

vent components. All components must be installed prior to operation. Basic steps are listed below to guide you through the installation of the flue pipe assembly provided with the unit.

1. Locate all venting components from the installation kit and carton.

2. Before connecting the vent pipe sections or components, verify the gasket is seated evenly inside the groove in the female end of all pieces.

3. Remove the vent cover from the back of the unit.

4. Insert the elbow into the flue adapter and tighten the clamp using a 5/16" nut driver.

5. Re-install the vent cover on the back of the unit.

6. Remove the provided screws from the vent cover and use them to install the wall strap.

 CAUTION

7. Slide the flue pipe through the wall strap and insert it into the elbow, tighten clamp.

8. Install the bird screen into the top of the vent and tighten the clamp.

Figure 2-3 Install Flue Pipe Assembly - Models 701 - 801

Outdoor Armor Water Heater Installation & Operation Manual

2 Prepare water heater (continued)

Gas conversions

 WARNING

Table 2A LP Conversion Table

Models 151 - 286

1. Remove the top and front access covers from the unit (Phillips screwdriver required for removal).

2. Remove the three screws securing the gas valve to the venturi (FIG. 2-4).

3. Locate the propane orifice disk from the conversion kit bag. Verify that the stamping on the orifice disk matches the water heater size (151 – 286) (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. 2-4).

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

 WARNING

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 151 - 400 you must install a propane orifice to operate the outdoor water heater on propane gas. Verify when installing that the orifice size marking matches water heater size (Models 151 – 400, Table 2A).

The 501 - 801 Models do not require an orifice installation for propane operation, but they will require a valve adjustment.

LP Conversion Table

Model LP Orifice Stamping

151 150

200 210 / W150

286 285

400 8.0

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.

Figure 2-4 Installing Propane Orifice - Models 151 - 286

Model 400

1. Remove the top and front access covers from the unit (Phillips screwdriver 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. 2-5 on page 12).

3. Remove the four screws securing the gas valve to the venturi (FIG. 2-5).

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).

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. 2-5.

6. Reposition the gas valve against the venturi and replace the screws (FIG. 2-5) 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. 2-5).

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.

 WARNING

 DANGER

After converting to LP, check combustion per the Start-up procedure in Section 7 of this manual. Failure to check and verify combustion could result in severe personal injury, death, or substantial property damage.

Armor 400: 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.

Outdoor Armor Water Heater Installation & Operation Manual

2 Prepare water heater

Figure 2-5 Installing Propane Orifice - Model 400

Model 501

1. Remove the top access cover from the unit (Phillips screwdriver 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. 2-6).

3. Use a combustion analyzer to verify CO2 is within the range of 9.6 – 10.5%. If not, adjust the screw

counterclockwise incrementally to raise CO2 and clockwise to lower CO2 (FIG. 2-6).

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

4. Use a combustion analyzer to verify CO2 is within the range of 9.6 – 10.5%. If not, adjust the screw counterclockwise incrementally to raise CO2 and clockwise to lower CO2 (FIG. 2-7).

5. 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.

6. Replace the gas valve cover along with the top access cover.

 WARNING

Figure 2-7 Gas Valve Adjustment - Models 601 - 801

COVER

ALLEN WRENCH

ADJUSTMENT SCREW

Figure 2-6 Gas Valve Adjustment - Model 501

Models 601 - 801

1. Remove the top access cover from the unit (Phillips screwdriver required for removal).

2. Remove the cover on top of the gas valve (FIG. 2-7).

3. Turn the adjustment screw on top of the gas valve clockwise one and three quarter (1 3/4) turns on the 601 Model, one and a half (1 1/2) turns on the 701 Model, and one turn on the 801 Model (see FIG. 2-7).

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. 2-8 below.

Figure 2-8 Leveling Legs on the Water Heater

Outdoor Armor Water Heater Installation & Operation Manual

3 System piping

System water piping methods

Observe a minimum of 1/4 inch clearance around all un-insulated hot water pipes when openings around the pipes are not protected by non-combustible materials.

General piping information

Basic steps are listed below along with illustrations on the following pages (FIG.’s 3-6 thru 3-10), which will guide you through the installation of the outdoor water heater.

1. Connect the cold water supply to the inlet side of the water heater.

2. Connect the hot water supply to the outlet side of the water heater.

3. Install a backflow preventer on the cold feed make-up water line.

4. Install the factory supplied pump as shown in FIG.’s 3-6 thru 3-10. If pump is installed outdoors use pump cover, reference the Pump Cover Installation section on this page.

5. Install an expansion tank on the system supply. Consult the tank manufacturer’s instruction for specific information relating to tank installation. Size the expansion tank for the required system volume and capacity.

6. Install a drain valve at the lowest point of the system.

7. This appliance is supplied with a relief valve sized in accordance with ASME Boiler and Pressure Vessel Code, Section IV (“Heating Boilers”). Pipe the discharge of the safety relief valve to a suitable drain to prevent injury in the event of pressure relief. Pipe the discharge to a drain. Provide piping that is the same size as the safety relief valve outlet. Never block the outlet of the safety relief valve.

Figure 3-1 Pump Cover Installation - Models 151 - 286

Figure 3-2 Pump Cover Installation - Models 400 - 801

Pump cover installation reference FIG.’s 3-1 and 3-2 for

pump cover installation)

If the water heater was purchased with a pump, please follow the instructions below to install the pump and outdoor cover assembly. If a field supplied pump is used, ensure that it is installed per the manufacturer’s specification in regard to indoor or outdoor location. An outdoor rated pump is recommended.

1. Locate the pump, pump cover assembly, flange kit and additional mounting nuts.

2. Before installing the pump, ensure the intended piping location allows room for the sheet metal cover assembly without interference.

3. Install the pump with the provided flanges and hardware.

4. Mount the pump cover base sheet metal aligning the holes for the piping and the bolts.

5. Using additional nuts, secure the sheet metal to the pump bolts.

6. Install the sheet metal top on the base with the provided screws (10x).

 WARNING

See the *piping illustrations included in this section, FIG.’s 3-6 thru 3-10 for suggested guidelines in piping the outdoor water heater.

NOTICE

The relief valve, tee and other necessary fittings are shipped in the install kit with the water heater and are to be field installed.

*Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes.

Flow switch and relief valve installation

Basic steps are listed below to guide you through the installation of the flow switch and relief valve provided with the unit.

1. Install the tee with the 3/4 inch fitting positioned vertically and on the top as shown in FIG. 3-3.

2. Install the relief valve into the 3/4 inch fitting of the tee installed in Step 1 (FIG. 3-3).

3. Install the close nipple on the downstream side of the temperature and pressure relief valve tee (FIG. 3-3).

4. Install the tee with the 1 inch fitting positioned vertically and on the top (FIG. 3-3).

Outdoor Armor Water Heater Installation & Operation Manual

3 System piping

5. Attach the paddle to the flow switch per the manufacturer’s instructions. Reference Table 3A to select the correct paddle for the pipe size used (consult the manufacturer’s instructions for a detailed explanation). For Example: If using a 1 1/4 inch pipe size (Models OAN151 - OAN200) select paddle #1.

6. Install the assembled flow switch into the 1 inch fitting of the tee installed in Step 4 (see FIG. 3-3).

NOTICE

Figure 3-3 Flow Switch and Relief Valve Installation

Be sure to install flow switch so that the arrow on the flow switch is pointing in the direction of the flow (see FIG. 3-4).

NOTICE

Turn the sensitivity screw clockwise to increase the flow rate required to activate the switch. Turn the sensitivity screw counterclockwise to decrease the flow rate required to activate the switch.

Figure 3-4 Flow Switch Adjustment

NORMALLY OPEN

GROUND

SENSITIVITY ADJUSTMENT

Flow switch adjustment

Refer to Table 3A for the proper setting of the sensitivity screw. For reference, the position of the screw prior to setting should be turned clockwise with a Phillips driver until it stops (FIG. 3-4). Proceed to turn the screw counterclockwise the amount of turns listed in Table 3A based on the model.

Consult the manufacturer’s instructions for wiring the flow switch to your system.

COMMON

NORMALLY CLOSED

Scalding

This water heater can deliver scalding temperature water at any faucet in the system. Be careful whenever using hot water to avoid scalding injury. Certain appliances such as dishwashers and automatic clothes washers may require increased temperature water. By setting the thermostat on this water heater to obtain the increased temperature water required by these appliances, you may create the potential for scald injury. To protect against injury, you should install a mixing valve in the water system. This valve will reduce point of discharge temperature by mixing cold and hot water in branch supply lines. Such valves are available from the local plumbing supplier.

Figure 3-5 Scald Warning Label Located on the Appliance

Table 3A Paddle Size / Sensitivity Screw Adjustment

MODEL PADDLE SIZE

Note: Paddles are included with the flow switch.

151 #1 9 turns 200 #1 6 turns 286 #3 8¾ turns 400 #1 8 turns 501 #1 7½ turns 601 #1 7 turns 701 #1 6½ turns 801 #1 5½ turns

SENSITIVITY SCREW

ADJUSTMENT

Outdoor Armor Water Heater Installation & Operation Manual

3 System piping (continued)

The following chart (Table 3B) details the relationship of water temperature and time with regard to scald injury and may be used as a guide in determining the safest water temperature for your applications.

Table 3B Approximate Time / Temperature Scald Chart

APPROXIMATE TIME / TEMPERATURE

RELATIONSHIPS IN SCALDS

120°F More than 5 minutes 125°F 1 1/2 to 2 minutes 130°F About 30 seconds 135°F About 10 seconds 140°F Less than 5 seconds 145°F Less than 3 seconds 150°F About 1 1/2 seconds 155°F About 1 second

Water chemistry

NOTICE

Heating of high hardness and/or high total dissolved solids water may require a larger circulating pump, and a revised temperature rise specification based on the water chemistry of the water to be heated.

Water with a hardness of less than 5 grains per gallon will usually have a pH which can be aggressive and corrosive causing non-warrantable damage to the pump, and associated piping. Corrosion due to water chemistry generally shows up first in the hot water system because heated water increases the rate of corrosive chemical reactions.

The required temperature rise and the standard circulating pump are sized based on the heating of potable water with a hardness of 5 to 25 grains per gallon and a total dissolved solids not exceeding 350 ppm. Consult the manufacturer when heating potable water exceeding these specifications.

Table 3C Water Heater Pump Applications / Recommended Temperature Rise

Piping components

Water heater system piping:

Water heater system piping MUST be sized per the pipe requirements listed in FIG.’s 3-9 and 3-10. Reducing the pipe size can restrict the flow rate through the water heater, causing inadvertent high limit shutdowns and poor system performance.

Check valves:

Field supplied. Check valves are recommended for installation as shown in FIG.’s 3-6 thru 3-10.

Water heater isolation valves:

Field supplied. Full port ball valves are required. Failure to use full port ball valves could result in a restricted flow rate through the water heater.

Anti-scald mixing valve:

Field supplied. An anti-scald mixing valve is recommended when storing domestic hot water above 115°F.

Unions:

Field supplied. Recommended for unit serviceability.

Temperature and pressure relief valve:

Factory supplied on water heaters. The temperature and pressure relief valve is sized to ASME specifications. Storage tanks may require additional valves depending on local codes.

Tank sensor:

Lochinvar supplies a tank sensor. The tank sensor must be installed in the tapping provided in the lower 25% of the storage tank to achieve proper operation. As shipped from the factory, the tank sensor is in the literature package shipped with the unit. Placing the sensor in the tapping provided on the storage tank will improve temperature response and prevent short cycles of operation.

Water Heater Pump Applications

Model

*Pipe

Armstrong Grundfos

Size

151 1-1/4" E8 -- 16 16.6 18°F

200 1-1/4" E8 -- 21 11.8 18°F

286 2" E17 -- 30 17.1 18°F

400 2" E24 -- 39 21 18°F

501 2" E22 -- 53 26 18°F 601 2" E22 -- 53 26 22°F 701 2" -- TP 40-160 63 32 22°F 801 2" -- TP 40-160 67 31 24°F

NOTICE

Pump sizing and flow requirements are based on 45 feet of piping, 4 - 90° elbows, and 2 - fully ported ball valves.

Flow Rate

(GPM)

Loss

(FT/HD)

Temp.

Rise

3 System piping

Figure 3-6 Single Heater - Single Tank

Outdoor Armor Water Heater Installation & Operation Manual

COLD WATER

THERMOMETER

HOT WATER

SUPPLY

UNION

(TYPICAL)

TEMPERATURE

& PRESSURE

RELIEF VALVE

(TYPICAL)

STORAGE

TANK

SUPPLY

MIXING VALVE

FLOW CHECK

VALVE (TYPICAL)

BUILDING RETURN

EXPANSION TANK

BALL VALVE (TYPICAL)

WATER

HEATER

CIRCULATOR

FLOW

SWITCH

WATER

HEATER

 CAUTION

NOTICE

IMG01145

DRAIN

Y-STRAINER

[RECOMMENDED]

The piping will not support the weight of the water heater circulator pump. Do not attempt to support the weight of the water heater circulator pump with the piping or its accessories. Refer to the pump manufacturer’s installation instructions. Failure to comply could result in severe personal injury, death, or substantial property damage.

Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment. The installer must follow all manufacturer’s instructions for each system component. The installer is responsible for compliance with local codes.

Indoor tank shown for illustration purposes.

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