Lochinvar WAL125PM Service Manual
WA-SER Rev A
Service Manual
Models: 125 - 200
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
Wall Mount 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 ........................ 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 Wall Mount 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
Hazard definitions
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
Revision Notes .................................................. Back Cover
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.
2
Please read before proceeding
Service Manual
WARNING
Installer – Read all instructions,
including this manual and the Armor
Wall Mount 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 Wall Mount 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.
3
What is in this manual?
Service Manual
Service
The Armor wall mount 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 wall mount operation
• General
• Data Logging
• Functions
• DHW Settings
• Anti-Cycling
• Control Modes
• Circulation Pumps
• BMS
• 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
4
1 Service
The Armor wall mount display
Service Manual
RESET KEY
NAVIGATION DIAL
(PRESS OR TURN)
STANDBY
TANK: 125°F (130)
MENU
LEFT SELECTED KEY
(SOFT KEY)
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):
SETPOINTS
SHDN
RIGHT SELECTED KEY
(SOFT KEY)
IMG00459
MENU = Left SELECT Key
SETPOINTS = NAVIGATION Dial - Pressing Down
SHDN = Right SELECT Key
5
1 Service
E
Control inputs
GAS PRESSURE SWITCH
DHW THERMOSTAT
FLOW SW ITCH
TAN K SE NS OR
Service Manual
LOW VOLTAGE
CONNECTION
BOARD
BUILDING MANAGEMENT
SYSTEM
LOW WATER CUTOFF
INLET TEMPERATURE
SENSOR
OUTLET TEMPERATURE /
HIGH LIMIT SENSOR
FLUE GAS SENSOR
AIR PRESSURE SWITCH
LOUVER PROVING SWITCH
FLAME SENSOR
BLOCKED DRAIN SWITCH
SMART SYSTEM
CONTROL MODUL
PC INTERFACE
6
DISPLAY PANEL
MENU
SETPOINTS
SHDN
1 Service (continued)
Control outputs
Service Manual
ALARM BELL
LOW VOLTAGE
CONNECTION
BOARD
LOUVER RELAY
RUN TIME CONTACTS
BUILDING MANAGEMENT
SYSTEM
BUILDING RECIRCULATION
PUMP
WATER HEATER PUMP
SMART SYSTEM
CONTROL MODULE
IGNITOR
BLOWER
GAS VALVE
MENU
SETPOINTS
SHDN
DISPLAY PANEL
PC INTERFACE
7
1 Service
General Operation
How the water heater operates
The Armor wall mount 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
Service Manual
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)
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.
Please note that the brackets ([]) denote
screen status.
8
1 Service (continued)
Table 1A Sequence of operation
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 the prepurge cycle.
Service Manual
4. The control starts the trial for ignition by firing the spark
electrode and opening the gas valve.
5. If flame is not detected after the sparking ends, the control will
perform a postpurge, then start another prepurge cycle and try
to light the burner again.
6. If flame is detected, it holds the firing rate steady for a few
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 the postpurge
period.
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.
9
1 Service
Display panel menu access
Table 1B Use this procedure to access menus from the display panel
Service Manual
BUTTON
SCREEN
STATUS
[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).
OPERATION DISPLAY
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.
10
Service Manual
1 Service (continued)
Display panel parameter access
Table 1C This is a typical example of accessing a parameter, shown for parameter DHW Settings, TANK MIN Setpt
BUTTON
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.
SCREEN
STATUS
OPERATION DISPLAY
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. The TANK
MIN SETPT setting will begin to flash.
>
>
Rotate the NAVIGATION dial to the desired
temperature.
[SAVE] Press the RIGHT SELECT soft key [SAVE] one time.
[EXIT]
[HOME]
Press the LEFT SELECT soft key [EXIT] if more
changes are to be made.
When finished making changes, press the LEFT
SELECT soft key [HOME].
11
Service Manual
1 Service
Parameter table
Table 1D This table lists SMART SYSTEM control module parameters and where to access them
Menu Description
Time and Date 14 Yes Yes Yes Yes
Software Version (read only) 14 No No Yes No
Temperature Units (ºC/ºF) 14 Yes Yes Yes Yes
DHW Night Setback Offset 14 No No Yes Yes
GENERAL
DHW Night Setback On Times 14 No No Yes Yes
DHW Night Setback Off Times 14 No No Yes Yes
Display Timeout 15 No No Yes Yes
Reset Log Errors 15 No No Yes Yes
DATA
LOGGING
Service Mode Delay 15 No No Yes Yes
See
Page
User Access Installer Access
Display Modify Display Modify
Freeze Protection Pump On 15 No No Yes Yes
Freeze Protection Burner On 15 No No Yes Yes
FUNCTIONSDHW SETTINGS
Freeze Protection Burner Differential 15 No No Yes Yes
Tank Set Point 15 Yes Yes Yes Yes
Tank Set Point Offset 15 Yes Yes Yes Yes
Tank Set Point Differential 15 No No Yes Yes
Tank Minimum Set Point 15 No No Yes Yes
Tank Maximum Set Point 15 No No Yes Yes
Anti-Cycling Time 16 No No Yes Yes
ANTI-
Anti-Cycling Override Differential 16 No No Yes Yes
CYCLING
12
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