Table Of Contents; Hazard Definitions - Lochinvar 150 - 500 Installation & Operation Manual

HAZARD DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2
PLEASE READ BEFORE PROCEEDING . . . . . . . . . . . . 3
THE ARMOR WATER HEATER -- HOW IT WORKS . . . . 4
RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1. DETERMINE WATER HEATER LOCATION
Provide Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Provide Air Openings to Room . . . . . . . . . . . . . . . . . . . . 10
Flooring and Foundation . . . . . . . . . . . . . . . . . . . . . . . . 10
Residential Garage Installation . . . . . . . . . . . . . . . . . . . . 10
Vent and Air Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Prevent Combustion Air Contamination . . . . . . . . . . . . . . 10
Corrosive Contaminants and Sources . . . . . . . . . . . . . . . 11
Removing a Water Heater from Existing Common Vent . 11
2. PREPARE WATER HEATER
Remove Water Heater from Wood Pallet . . . . . . . . . . . . 12
Gas Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Leveling the Water Heater . . . . . . . . . . . . . . . . . . . . . 13
3. GENERAL VENTING
Direct Venting Options . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Install Vent and Combustion Air Piping . . . . . . . . . . . . . . 15
Vent Piping Materials . . . . . . . . . . . . . . . . . . . . . . . . . 15
Requirements for Installation in Canada . . . . . . . . . . . . . 15
Air Intake/Vent Connections . . . . . . . . . . . . . . . . . . . . . . 16
Air Inlet Pipe Materials . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Min./Max. Combustion Air & Vent Piping Lengths . . . . . . 17
Removing from Existing Vent . . . . . . . . . . . . . . . . . . . . . 17
Vent and Air Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4. SIDEWALL DIRECT VENTING
Vent/Air Termination - Sidewall . . . . . . . . . . . . . . . . . . . . 18-21
Determine Location . . . . . . . . . . . . . . . . . . . . . . . . . . 18-19
Prepare Wall Penetrations . . . . . . . . . . . . . . . . . . . . . 20
Termination and Fittings . . . . . . . . . . . . . . . . . . . . . . . 20
Multiple Vent/Air Terminations . . . . . . . . . . . . . . . . . . 20
Sidewall Termination - Optional Concentric Vent . . . . . . 21-23
5. VERTICAL DIRECT VENTING
Vent/Air Termination - Vertical . . . . . . . . . . . . . . . . . . . . . 24-25
Determine Location . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Prepare Roof Penetrations . . . . . . . . . . . . . . . . . . . . . 25
Termination and Fittings . . . . . . . . . . . . . . . . . . . . . . . 25

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 indicates an imminently hazardous situation which, if not avoided, will result in death or serious
DANGER
injury.
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious
WARNING
injury.
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate
CAUTION
injury.
CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not
CAUTION
avoided, may result in property damage.
NOTICE indicates special instructions on installation, operation, or maintenance that are important but not
NOTICE
related to personal injury or property damage.
2
Contents
Multiple Vent/Air Terminations . . . . . . . . . . . . . . . . . . 25
Vertical Termination - Optional Concentric Vent . . . . . . . 26-27
6. HYDRONIC PIPING
System Water Piping Methods . . . . . . . . . . . . . . . . . . . . 28
Flow Switch and Relief Valve Installation . . . . . . . . . . . . 28
Flow Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Water Chemistry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Piping Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7. GAS CONNECTIONS
Connecting Gas Supply Piping . . . . . . . . . . . . . . . . . . . . 35
Natural Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Pipe Sizing for Natural Gas . . . . . . . . . . . . . . . . . . . . 36
Natural Gas Supply Pressure Requirements . . . . . . . 36
Propane Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Pipe Sizing for Propane Gas . . . . . . . . . . . . . . . . . . . 36
Propane Supply Pressure Requirements . . . . . . . . . . 36
Check Inlet Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
High and Low Gas Pressure Switches . . . . . . . . . . . . . . 38
Gas Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 38
8. FIELD WIRING
Line Voltage Connections . . . . . . . . . . . . . . . . . . . . . . . . 39
Low Voltage Connections . . . . . . . . . . . . . . . . . . . . . . . . 40
Wiring of the Cascade . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
9. CONDENSATE DISPOSAL
Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
10. STARTUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44-49
11. OPERATING INFORMATION
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Cascade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51-52
Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Armor Water Heater Control Module . . . . . . . . . . . . . . . . 54
Status Display Screens . . . . . . . . . . . . . . . . . . . . . . . . . . 55-57
12. MAINTENANCE
Maintenance & Annual Startup . . . . . . . . . . . . . . . . . . . . 58-61
13. DIAGRAMS
Ladder Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Revision Notes . . . . . . . . . . . . . . . . . . . . . . . . . Back Cover