Table of Contents
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AW-I-O Rev I
Installation & Operation
Manual
Models: 150 - 500
Starting Serial #H07H10046464
This manual must only be used by a
WARNING
qualified heating installer / service
technician. Read all instructions,
including this manual and the
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.
Save this manual for future reference.
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Table of Contents
Related Manuals for Lochinvar 150 - 500
Summary of Contents for Lochinvar 150 - 500
- Page 1 AW-I-O Rev I Installation & Operation Manual Models: 150 - 500 Starting Serial #H07H10046464 This manual must only be used by a WARNING qualified heating installer / service technician. Read all instructions, including this manual and the Armor Water Heater Service Manual, before installing.
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Page 2: Table Of Contents
Contents HAZARD DEFINITIONS ......2 Multiple Vent/Air Terminations ....25 PLEASE READ BEFORE PROCEEDING . -
Page 3: Please Read Before Proceeding
Installation & Operation Manual Please read before proceeding Installer – Read all instructions, including When servicing the water heater – WARNING this manual and the Armor Water Heater • To avoid electric shock, disconnect electrical supply Service Manual, before installing. Perform before performing maintenance. -
Page 4: The Armor Water Heater - How It Works
Installation & Operation Manual The Armor Water Heater - How it works... Stainless steel heat exchanger 16. SMART Control Module Allows water flow through specially designed The SMART Control responds to internal and external signals coils maximum heat transfer, while providing and controls the blower, gas valve, and pumps to meet the protection against flue gas corrosion. - Page 5 Installation & Operation Manual The Armor Water Heater - How it works... (continued) Models 150 - 285 Front View - Models 150 - 285 Rear View - Models 150 - 285 Left Side (inside unit) - Models 150 - 285 Right Side (inside unit) - Models 150 - 285...
- Page 6 Installation & Operation Manual The Armor Water Heater - How it works... Model 399 Rear View - Model 399 Left Side (inside unit) - Model 399 Model 500 Left Side (inside unit) - Model 500 Rear View - Model 500...
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Page 7: Ratings
Installation & Operation Manual Ratings Model Number Input Modulation Btu/hr Water Content Water Vent/Air Size Gallons Connections Connections Note: Change “N” to “L” for L.P. gas models. (Note 2, 3) (Note 1) AWN150PM 30,000 - 150,000 1-1/4" 1/2" 3" AWN199PM 40,000 - 199,999 1-1/4"... -
Page 8: Determine Water Heater Location
Installation & Operation Manual Determine water heater location Installation must comply with: This appliance is certified as an indoor WARNING appliance. Do not install the appliance • Local, state, provincial, and national codes, laws, regulations, outdoors or locate where the appliance will and ordinances. - Page 9 Installation & Operation Manual Determine water heater location (continued) Figure 1-1 Closet Installation - Minimum Required Clearances For closet installations, CPVC WARNING material MUST BE used in a closet structure elevated temperatures. Failure to follow this warning could result in fire, personal injury, or death.
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Page 10: Provide Air Openings To Room
Installation & Operation Manual Determine water heater location Provide air openings to room: Residential garage installation Armor water heater alone in equipment room Precautions Take the following precautions when installing the appliance in 1. No air ventilation openings into the equipment room are a residential garage. -
Page 11: Corrosive Contaminants And Sources
Installation & Operation Manual Determine water heater location (continued) Table 1A Corrosive Contaminants and Sources When removing a water heater from existing common vent system: Products to avoid: Do not install the Armor water heater into DANGER Spray cans containing chloro/fluorocarbons a common vent with any other appliance. -
Page 12: Prepare Water Heater
Installation & Operation Manual Prepare water heater Remove water heater from wood pallet Table 2A LP Conversion Table 1. After removing the outer shipping carton from the water LP Conversion Table heater, remove the parts box. Model LP Orifice Stamping 2. -
Page 13: Leveling The Water Heater
Installation & Operation Manual Prepare water heater (continued) Model 399 Model 500 1. Remove the top and front access covers from the unit (no tools 1. Remove the top access cover from the unit (no tools required for removal). required for removal). 2. -
Page 14: General Venting
Installation & Operation Manual General venting Direct venting options Figure 3-1 Vertical Direct Venting (Two-Pipe Vertical Figure 3-2 Sidewall Direct Venting (Two-Pipe Sidewall Termination) - See page 24 for more details Termination) - See page 18 for more details Figure 3-4 Concentric Sidewall Termination - See page Figure 3-3 Concentric Vertical Termination - See page 21 for more details 26 for more details... -
Page 15: Install Vent And Combustion Air Piping
For closet and alcove installations, CPVC WARNING material MUST BE used in a closet/alcove The 3" Concentric Vent Kit available from Lochinvar (see structure. Failure to follow this warning Section 4 – Sidewall Termination – Optional Concentric could result in fire, personal injury, or death. -
Page 16: Air Intake/Vent Connections
Installation & Operation Manual General venting Figure 3-7 Near Water Heater Venting Model 500 Combustion air piping to the outside MUST NOTICE BE used. Use of combustion air from the room via louvers, plenums, or any other device is not authorized. Air intake/vent connections VENT Combustion Air Intake Connector (FIG.’s 3-5 thru 3-7) -... -
Page 17: Min./Max. Combustion Air & Vent Piping Lengths
Installation & Operation Manual General venting (continued) Vent, air piping and termination: Minimum Maximum allowable combustion air and vent piping lengths The Armor water heater vent and air piping can be installed are as follows: through the roof or through a sidewall. Follow the procedures in this manual for the method chosen. -
Page 18: Sidewall Direct Venting
Installation & Operation Manual Sidewall direct venting Figure 4-1A Sidewall Termination of Air and Vent Vent/air termination – sidewall Follow instructions below when determining TO BOILER WARNING INTAKE AIR vent location to avoid possibility of severe CONNECTION personal injury, death, or substantial FROM BOILER property damage. - Page 19 Installation & Operation Manual Sidewall direct venting (continued) Vent/air termination – sidewall Figure 4-2B Alternate Clearance to Gravity Air Inlets w/Field Supplied Fittings Figure 4-1C Alternate Venting Arrangement (if Space Allows) w/Field Supplied Fittings TO BOILER INTAKE AIR COUPLING CONNECTION 12”...
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Page 20: Prepare Wall Penetrations
Installation & Operation Manual Sidewall direct venting Prepare wall penetrations Figure 4-4B Alternate Sidewall Termination Assembly Use the factory supplied wall plate as a template to locate w/Field Supplied Fittings the vent and air intake holes and mounting holes. ELBOW Air pipe penetration: AIR PIPING Cut a hole for the air pipe. -
Page 21: Sidewall Termination - Optional Concentric Vent
4. Cut one (1) hole (5 inch diameter for #CVK3003 Description and usage installations or 7 inch diameter for #CVK3007 installations) Lochinvar offers optional concentric combustion air and vent into the structure to install the termination kit. pipe termination kits (Factory Kit #CVK3003 for 3" diameter - Models 150 - 199 and #CVK3007 for 4"... - Page 22 Installation & Operation Manual Sidewall direct venting Sidewall termination – optional concentric vent Figure 4-9 Concentric Vent Dimensional Drawing - Figure 4-10 Concentric Vent Dimensional Drawing - Models 150 - 199 Models 285 - 500 "A" "B" DIA. "C" DIA. "D"...
- Page 23 Installation & Operation Manual Sidewall direct venting (continued) Sidewall termination – optional concentric vent Figure 4-12 Concentric Vent Sidewall Attachment Note: CVK3003 shown for illustration purposes. Multiventing sidewall terminations DO NOT use field-supplied couplings to CAUTION extend pipes. Airflow restriction will When two (2) or more direct vent appliances are vented near occur and may cause intermittent each other, each appliance must be individually vented (see...
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Page 24: Vertical Direct Venting
Installation & Operation Manual Vertical direct venting Vent/air termination – vertical Follow instructions below when determining Rooftop vent and air inlet terminations WARNING WARNING vent location to avoid possibility of severe must terminate in the same pressure zone. personal injury, death or substantial property damage. -
Page 25: Prepare Roof Penetrations
Installation & Operation Manual Vertical direct venting (continued) Vent/air termination – vertical Multiple vent/air terminations Prepare roof penetrations 1. When terminating multiple Armor water heaters, terminate Air pipe penetration: each vent/air connection as described in this manual Cut a hole for the air pipe. Size the air pipe hole as (FIG. -
Page 26: Vertical Termination - Optional Concentric Vent
Vertical direct venting Vertical termination – optional concentric vent Description and usage Lochinvar offers an optional concentric combustion air and vent 3. Cut one (1) hole (5 inch diameter for #CVK3003 pipe termination kit. Both combustion air and vent pipes must installations or 7 inch diameter for #CVK3007 installations) attach to the termination kit. - Page 27 Installation & Operation Manual Vertical direct venting (continued) Vertical termination – optional concentric vent Do not operate the appliance with the rain DO NOT use field-supplied couplings to CAUTION WARNING removed recirculation extend pipes. Airflow restriction will combustion products may occur. Water occur.
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Page 28: System Water Piping Methods
Installation & Operation Manual System piping Install the assembled flow switch into the 1 inch fitting of System water piping methods the tee installed in Step 4 (see FIG. 6-1). Observe a minimum of 1 inch clearance around all un-insulated Be sure to install flow switch so that the arrow hot water pipes when openings around the pipes are not NOTICE... -
Page 29: Water Chemistry
125°F 1 1/2 to 2 minutes Tank sensor: 130°F About 30 seconds Lochinvar supplies a tank sensor. The tank sensor must be 135°F About 10 seconds installed in the tapping provided in the lower 25% of the storage 140°F Less than 5 seconds tank to achieve proper operation. - Page 30 Installation & Operation Manual System piping Figure 6-4 Single Heater - Single Tank (2 Temperature) 180° HOT WATER FLOW CHECK VALVE (TYPICAL) SUPPLY HIGH TEMPERATURE THERMOMETER 140° HOT (TYPICAL) BUILDING RETURN STORAGE WATER TANK SUPPLY BALL VALVE MIXING (TYPICAL) TEMPERATURE VALVE &...
- Page 31 Installation & Operation Manual System piping (continued) Figure 6-5 Single Heater - Single Tank FLOW CHECK COLD WATER VALVE (TYPICAL) SUPPLY EXPANSION TANK MIXING VALVE THERMOMETER BUILDING RETURN BALL VALVE (TYPICAL) HOT WATER WATER HEATER SUPPLY CIRCULATOR UNION (TYPICAL) TEMPERATURE &...
- Page 32 Installation & Operation Manual System piping Figure 6-6 Single Heater - Double Tank COLD WATER FLOW CHECK SUPPLY VALVE (TYPICAL) EXPANSION TANK MIXING VALVE THERMOMETER WATER HEATER CIRCULATOR FLOW SWITCH HOT WATER SUPPLY UNION (TYPICAL) TEMPERATURE & PRESSURE RELIEF VALVE (TYPICAL) WATER HEATER...
- Page 33 Installation & Operation Manual System piping (continued) Figure 6-7 Double Heater - Single Tank Number of Units Model Required Pipe Sizes in NPT 1 1/2" 2" 2" 2 1/2" 2 1/2" 3" 3" 1 1/2" 2" 2 1/2" 2 1/2" 3"...
- Page 34 Installation & Operation Manual System piping Figure 6-8 Double Heater - Double Tank Number of Units Model Required Pipe Sizes in NPT 1 1/2" 2" 2" 2 1/2" 2 1/2" 3" 3" 1 1/2" 2" 2 1/2" 2 1/2" 3" 3"...
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Page 35: Gas Connections
Installation & Operation Manual Gas connections Connecting gas supply piping Figure 7-3 Gas Supply Piping - Model 500 1. Remove the top access panel and refer to FIG.’s 7-1 thru 7-3 to pipe gas to the water heater. Install ground joint union for servicing, when required. -
Page 36: Natural Gas
Installation & Operation Manual Gas connections Failure to apply pipe sealing compound as Natural gas: WARNING detailed in this manual can result in severe Pipe sizing for natural gas personal injury, death, or substantial property damage. 1. Refer to Table 7A for pipe length and diameter. Based on Armor water heaters are typically shipped rated water heater input (divide by 1,000 to obtain cubic feet WARNING... -
Page 37: Check Inlet Gas Supply
Installation & Operation Manual Gas connections (continued) Table 7A Natural Gas Pipe Size Chart Single Unit Nominal Natural Gas Pipe Capacity Chart Iron Pipe Length of Pipe in Straight Feet for 1/2 PSI Size (Inches) 1-1/4 1400 1-1/2 2150 1500 1210 1020 4100... -
Page 38: Gas Pressure
Installation & Operation Manual Gas connections 17. Check burner performance by cycling the system while Gas pressure you observe burner response. The burner should ignite The gas pressure must remain between 4 inches w.c. (natural), promptly. Flame pattern should be stable. Turn system 8 inches w.c (LP) minimum and 14 inches w.c. -
Page 39: Field Wiring
Installation & Operation Manual Field wiring Installation must comply with: ELECTRICAL SHOCK HAZARD – For WARNING your safety, turn off electrical power 1. National Electrical Code and any other national, state, supply before making any electrical provincial, or local codes, or regulations. connections to avoid possible electric shock hazard. -
Page 40: Low Voltage Connections
Installation & Operation Manual Field wiring Low voltage connections High gas pressure switch 1. Route all low voltage wires through the knockouts in the 1. If a switch is provided to detect excessive gas pressure, rear of the water heater, as shown in FIG. 8-2. remove the jumper wire from the terminals on the connection board, and then connect them to its normally 2. -
Page 41: Runtime Contacts
Installation & Operation Manual Field wiring (continued) Runtime contacts The SMART SYSTEM control closes a set of dry contacts whenever the burner is running. This is typically used by Building Management Systems to verify that the water heater is responding to a call for heat. Alarm contacts The SMART SYSTEM control closes another set of contacts whenever the water heater is locked out or the power is... - Page 42 Installation & Operation Manual Field wiring Figure 8-3 Low Voltage Field Wiring Connections...
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Page 43: Condensate Disposal
Installation & Operation Manual Condensate disposal Condensate drain Use materials approved by the authority NOTICE having jurisdiction. In the absence of other authority, PVC and CPVC pipe must comply 1. This water heater is a high efficiency appliance that with ASTM D1785 or D2845. Cement and produces condensate. -
Page 44: Startup
Installation & Operation Manual Start-up Chlorine concentration less than 200 ppm Propane water heaters only – Your propane WARNING supplier mixes an odorant with the propane 1. Do not fill the water heater or operate with water to make its presence detectable. In some containing chlorine in excess of 200 ppm. - Page 45 Installation & Operation Manual Start-up (continued) Final checks before starting the water Check vent piping and air piping heater 1. Check for gastight seal at every connection, seam of air piping, and vent piping. Read the Armor Water Heater Service Manual to familiarize yourself with SMART SYSTEM control module operation.
- Page 46 Installation & Operation Manual Start-up Figure 10-2 Operating Instructions - Models 150 - 285...
- Page 47 Installation & Operation Manual Start-up (continued) Figure 10-3 Operating Instructions - Models 399 - 500...
- Page 48 Installation & Operation Manual Start-up Check flame and combustion (continued) Set water heater operation 4. Place the water heater into the active position by pressing Set tank set point temperature the SHUTDOWN button on the display board (FIG. 11-1, The UP and DOWN keys may be used during normal operation page 54) until WHR:Standby appears in the display to adjust the tank set point temperature.
- Page 49 Installation & Operation Manual Start-up (continued) Set clock Configuration of the cascade The SMART SYSTEM control has a built-in clock that it When installed in a Cascade system, the individual controls uses for its night setback feature and for logging events. must be programmed for cascade operation.
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Page 50: Operating Information
Installation & Operation Manual Operating information General Protection features How the water heater operates Outlet temperature, flue temperature, and temperature rise limiting The Armor water heater uses an advanced stainless steel heat exchanger and electronic control module that allows fully The outlet temperature is monitored by the water heater outlet condensing operation. -
Page 51: Cascade
Installation & Operation Manual Operating information (continued) Monitor external limits High limit operations Connections are provided on the connection board for When outlet temperature exceeds 200°F, high limit action external limits such as flow switch, gas pressure switches, occurs. The water heater shuts down until the outlet water cools and an auxiliary device proving switch. - Page 52 Installation & Operation Manual Operating information If the set point still cannot be met, the Leader will continue Access modes firing more Members until either the heat demand is met or all User water heaters on the Cascade are firing. As the heat demand decreases, the last water heater on will modulate down to 20% of The user can adjust water tank target temperature by using the its firing rate.
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Page 53: Sequence Of Operation
Installation & Operation Manual Operating information (continued) Sequence of operation OPERATION DISPLAY WHR: Standby 1. Upon a call for heat, the control turns on the water heater pump. OUT: 123.8F(129) 2. The control connects 120 VAC to the blower. The blower does not run at this time. -
Page 54: Armor Water Heater Control Module
Installation & Operation Manual Operating information Armor water heater control module Use the control panel (FIG. 11-1) to set temperatures, operating conditions, and monitor water heater operation. Figure 11-1 Control Panel... -
Page 55: Status Display Screens
Installation & Operation Manual Operating information (continued) Status display screens Status Display Screens By using the Previous/Next ( , ) arrow keys on the SMART SYSTEM display panel, you can navigate through the six (6) display screens. Each screen will contain two (2) viewable items. The following is a description of the individual items and what they can display: Screen Display shows:... - Page 56 Installation & Operation Manual Operating information Status Display Screens (cont’d) By using the Previous/Next ( , ) arrow keys on the SMART SYSTEM display panel, you can navigate through the six (6) display screens. Each screen will contain two (2) viewable items. The following is a description of the individual items and what they can display: Screen Display shows:...
- Page 57 Installation & Operation Manual Operating information (continued) Status Display Screens (cont’d) Operation of the cascade The water heater designated as the Leader will have two additional display screens that can be viewed. These screens will provide information regarding the operation of the Cascade. Each screen will contain two viewable items. The following is a description of the individual items and what they can display: Screen Display shows:...
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Page 58: Maintenance
Installation & Operation Manual Maintenance Maintenance and annual startup Table 12A Service and Maintenance Schedules Service technician Owner maintenance (see the following pages for instructions) General: • Address reported problems • Inspect interior; clean and vacuum if necessary; Daily • Check water heater area •... -
Page 59: Address Reported Problems
Installation & Operation Manual Maintenance (continued) Follow the service and maintenance procedures given throughout this manual and in component literature WARNING shipped with the water heater. Failure to perform the service and maintenance could result in damage to the water heater or system. Failure to follow the directions in this manual and component literature could result in severe personal injury, death, or substantial property damage. -
Page 60: Check Water System
Installation & Operation Manual Maintenance Failure to inspect for the above conditions Following installation, the valve lever must WARNING WARNING and have them repaired can result in severe be operated AT LEAST ONCE A YEAR to personal injury or death. ensure that waterways are clear. -
Page 61: Cleaning Heat Exchanger
Installation & Operation Manual Maintenance (continued) Cleaning heat exchanger Perform start-up and checks 1. Shut down water heater: 1. Start water heater and perform checks and tests specified in Section 10 - Start-up. • Follow the “To Turn Off Gas to Appliance” instructions for the water heater in Section 10 - Startup. -
Page 62: Diagrams
Installation & Operation Manual Diagrams Figure 13-1 Ladder Diagram JUNCTION BOX 120VAC NEUTRAL GROUND TERMINAL STRIP TERMINAL STRIP 120V SUPPLY "L" 120V SUPPLY "N" DHW PUMP RELAY PUMP "L" PUMP "N" PUMP TERMINAL TERMINAL STRIP STRIP INTEGRATED CONTROL ON / OFF DHW PUMP SWITCH RELAY COIL... -
Page 63: Wiring Diagram
Installation & Operation Manual Diagrams (continued) Figure 13-2 Wiring Diagram LOW VOLTAGE WARNING DISPLAY 120 VAC DISCONNECT POWER HIGH VOLTAGE BEFORE SERVICING INTEGRATED CONTROL JUNCTION BOX DEPICTS OPTIONAL ITEMS PUMP RELAY INTERFACE CONNECTION BOARD AUX. PUMP X1-5 DEVICE PILOT SUPPLY X1-4 CN4-8 X6-8... -
Page 64: Revision Notes
Revision Notes: Revision B (AW-I&O-Rev B) reflects the addition of the Dungs information to the manual. Revision C (AW-I&O-Rev C) reflects changes made to pages 30 and 31 (piping diagrams). Revision D (AW-I&O-Rev D) reflects changes made to Model 199 orifice.