Table of Contents
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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.
• 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.
Installation & Operation
LOW LEAD CONTENT
Manual
Models: 1000 - 1500
This manual must only be used
WARNING
by a qualified heating installer
/ service technician. Read all
instructions, including this manual
and the Armor X2 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.
AWX2-I-O Rev F
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Table of Contents
Related Manuals for Lochinvar Armor X2 AWN1000
Summary of Contents for Lochinvar Armor X2 AWN1000
- Page 1 AWX2-I-O Rev F Installation & Operation Manual Models: 1000 - 1500 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.
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Page 2: Table Of Contents
Contents 6. SYSTEM PIPING HAZARD DEFINITIONS..............2 System Water Piping Methods ............29 PLEASE READ BEFORE PROCEEDING ......3 General Piping Information ............. 29 THE ARMOR X2 WATER HEATER -- HOW IT WORKS 4-5 Scalding ....................29 RATINGS .................... 6 Water Chemistry ................ -
Page 3: Please Read Before Proceeding
Installation & Operation Manual Please read before proceeding Installer – Read all instructions, including WARNING WARNING DO NOT install units in rooms or this manual and the Armor X2 Water environments that contain corrosive Heater Service Manual, before installing. contaminants (see Table 1A on page 10). Perform steps in the order given. -
Page 4: The Armor X2 Water Heater - How It Works
Installation & Operation Manual The Armor X2 Water Heater - How it works... Access cover - front 23. Heat exchanger access covers Provides access to the gas train and the heat exchanger. Allows access combustion side heat Air intake adapter exchanger coils. - Page 5 Installation & Operation Manual The Armor X2 Water Heater - How it works... (continued) Models 1.0 - 1.3 - 1.5 IMG00134 Front View Rear View Right Side (inside unit) Left Side (inside unit)
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Page 6: Ratings
Installation & Operation Manual Ratings LOW LEAD CONTENT Water Connections Model Number Water Input Modulation Btu/hr Vent/Air Size Content Gas Connections Note: Change “N” to “L” for Gallons L.P. gas models. Inlet Outlet (Note 2, 3) (Note 1) AWN1000 100,000 - 1,000,000 2"... -
Page 7: 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 8 Installation & Operation Manual Determine water heater location Figure 1-1 Closet Installation - Minimum Required Clearances For closet installations, CPVC, WARNING polypropylene or stainless steel vent material MUST BE used in a closet structure due to elevated temperatures. Failure to follow this warning could result in fire, personal injury, or death.
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Page 9: Provide Air Openings To Room
Installation & Operation Manual Determine water heater location (continued) Provide air openings to room: Vent and air piping The Armor X2 requires a special vent system, designed for The Armor X2 alone in boiler room pressurized venting. 1. No air ventilation openings into the boiler room are The water heater is to be used for either direct vent installation needed when clearances around the Armor X2 are at least or for installation using indoor combustion air. -
Page 10: Corrosive Contaminants And Sources
Installation & Operation Manual Determine water heater location When using an existing vent system to Table 1A Corrosive Contaminants and Sources install a new water heater: Products to avoid: Failure to follow all instructions can result WARNING Spray cans containing chloro/fluorocarbons in flue gas spillage and carbon monoxide emissions, causing severe personal injury Permanent wave solutions... -
Page 11: Removing A Water Heater From Existing Common Vent
Installation & Operation Manual Determine water heater location (continued) When removing a water heater from existing common vent system: Do not install the Armor X2 into a DANGER common vent with any other appliance. This will cause flue gas spillage or appliance malfunction, resulting in possible severe personal injury, death, or substantial property damage. -
Page 12: Combustion And Ventilation Air Requirements
Installation & Operation Manual Determine water heater location Combustion ventilation requirements for appliances drawing air from the equipment room Provisions for combustion and ventilation air must be in accordance with Air for Combustion and Ventilation, of the latest edition of the National Fuel Gas Code, ANSI Z223.1, in Canada, the latest edition of CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment, or applicable provisions of the local building codes. - Page 13 Installation & Operation Manual Determine water heater location (continued) Where two openings are provided, one must be within 12" (30cm) of the ceiling and one must be within 12" (30cm) of the floor of the equipment room. Each opening must have net free area as specified in the chart below (Table 1B).
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Page 14: Prepare Water Heater
Installation & Operation Manual Prepare water heater Remove water heater from wood pallet 1. After removing the outer shipping carton from the water heater, remove the parts package (packaged parts inside the jacket of the water heater). To remove the water heater from the pallet: Remove the front door of the water heater. -
Page 15: General Venting
Installation & Operation Manual General venting Direct venting options - Sidewall Vent Figure 3-1 Two-Pipe Sidewall Termination - See page 23 for more details Direct venting options - Vertical Vent Figure 3-2 Two-Pipe Vertical Termination - See Figure 3-3 Vertical Vent, Sidewall page 27 for more details... -
Page 16: Install Vent And Combustion Air Piping
Installation & Operation Manual General venting Install vent and combustion air piping The Armor X2 water heater must be The Armor X2 water heater vent and air piping can be installed DANGER vented and supplied with combustion and through the roof or through a sidewall. Follow the procedures ventilation air as described in this section. -
Page 17: Requirements For Installation In Canada
Installation & Operation Manual General venting (continued) Sizing Requirements for installation in Canada The Armor X2 water heater uses model specific combustion air intake and vent piping sizes as detailed in Table 3A below. Installations must be made with a vent pipe system certified to ULC-S636. -
Page 18: Materials
Installation & Operation Manual General venting Materials Air inlet pipe materials: The PVC, CPVC, or ABS air inlet pipe should be cleaned and The air inlet pipe(s) must be sealed. Choose acceptable sealed with the pipe manufacturer’s recommended solvents combustion air inlet pipe materials from the following list: and standard commercial pipe cement for the material used. -
Page 19: Optional Room Air
Installation & Operation Manual General venting (continued) Optional room air Applications utilizing the Armor X2 water heater may be Table 3B Room Air Minimum / Maximum Allowable Air / installed with a single pipe carrying the flue products to the Vent Lengths outside while using combustion air from the equipment room. -
Page 20: Pvc/Cpvc
Installation & Operation Manual General venting PVC/CPVC Work from the water heater to vent or air termination. Do not exceed the lengths given in this manual for the This product has been approved for use with the PVC/CPVC air or vent piping. vent materials listed in Table 3C. -
Page 21: Polypropylene
Installation & Operation Manual General venting (continued) Polypropylene Use only the adapters and vent system listed WARNING in Tables 3E and 3F. DO NOT mix vent This product has been approved for use with polypropylene systems of different types or manufacturers. vent with the manufacturers listed in Table 3D. -
Page 22: Stainless Steel Vent
Installation & Operation Manual General venting Stainless steel vent Installation of a stainless steel vent system NOTICE should adhere to the stainless steel vent This product has been approved for use with stainless steel manufacturer’s installation instructions using FasNSeal vent systems. supplied with the vent system. -
Page 23: Sidewall Direct Venting
Installation & Operation Manual Sidewall direct venting Vent/air termination – sidewall Figure 4-1A PVC/CPVC/Centrotherm Sidewall Termination of Air and Vent Follow instructions below when WARNING TO BOILER Note: Available in 6" determining vent location to avoid INTAKE AIR diameter only. CONNECTION possibility of severe personal injury, death, or substantial property damage. - Page 24 Installation & Operation Manual Sidewall direct venting Vent/air termination – sidewall Figure 4-2A Clearance to Gravity Air Inlets Figure 4-1C Alternate Stainless Steel Sidewall Termination w/Field Supplied Fittings PVC/CPVC or ABS is acceptable air inlet pipe material. NOTICE 12" MIN. VENT / AIR TERMINATION TO BOILER INTAKE...
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Page 25: Prepare Wall Penetrations
Installation & Operation Manual Sidewall direct venting (continued) 8. PVC/CPVC terminations are designed to accommodate any Figure 4-3B Alternate Clearance to Forced Air Inlets w/ wall thickness of standard constructions per the directions Field Supplied Fittings found in this manual. IF LESS 9. -
Page 26: Multiple Vent/Air Terminations
Installation & Operation Manual Sidewall direct venting Multiple vent/air terminations Prepare wall penetrations (Alternate Field Supplied Options) 1. When terminating multiple Armor X2 water heaters Air pipe penetration: terminate each vent/air connection as described in this Cut a hole for the air pipe. Size the air pipe hole as manual (FIG. -
Page 27: Vertical Direct Venting
Installation & Operation Manual Vertical direct venting Vent/air termination – vertical Figure 5-1 PVC/CPVC/Polypropylene Vertical Termination of Air and Vent Follow instructions below when ALTERNATE INTAKE LOCATIONS: WARNING INTAKE PIPES MAY BE LOCATED determining vent location to avoid ANYWHERE WITHIN 24" (610 MM) possibility of severe personal injury, death OF VENT PIPE or substantial property damage. -
Page 28: Multiple Vent/Air Terminations
Installation & Operation Manual Vertical direct venting Multiple vent/air terminations Figure 5-3 Vertical Terminations with Multiple Water Heaters 1. When terminating multiple Armor X2 water heaters, terminate each vent/air connection as described in this manual (FIG. 5-3). 12" (305 MM) MINIMUM VERTICALLY FROM VENT OUTLET TO ANY AIR INLET Terminate all vent pipes at the same height... -
Page 29: System Piping
Installation & Operation Manual System piping System water piping methods Scalding This water heater can deliver scalding temperature water at any Observe a minimum of 1/4 inch clearance around all faucet in the system. Be careful whenever using hot water to avoid un-insulated hot water pipes when openings around the pipes scalding injury. -
Page 30: Water Chemistry
Tank sensor: Lochinvar supplies a tank sensor. The tank sensor MUST be installed 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. - Page 31 Installation & Operation Manual System piping (continued) Figure 6-2 Single Heater - Single Tank (2 Temperature) The piping will not support the weight of the water heater circulator pump. Do not attempt to support CAUTION the weight of the water heater circulator pump with the piping or its accessories. Refer to the pump manufacturer’s installation instructions.
- Page 32 Installation & Operation Manual System piping Figure 6-3 Single Heater - Single Tank The piping will not support the weight of the water heater circulator pump. Do not attempt to support CAUTION the weight of the water heater circulator pump with the piping or its accessories. Refer to the pump manufacturer’s installation instructions.
- Page 33 Installation & Operation Manual System piping (continued) Figure 6-4 Single Heater - Double Tank The piping will not support the weight of the water heater circulator pump. Do not attempt to support CAUTION the weight of the water heater circulator pump with the piping or its accessories. Refer to the pump manufacturer’s installation instructions.
- Page 34 Installation & Operation Manual System piping Figure 6-5 Double Heater - Single Tank Number of Units Model Required Pipe Sizes 4" 5" 6" 6" 8" 8" 8" 5" 6" 6" 6" 8" 8" 8" 5" 6" 6" 8" 8" 8" 8"...
- Page 35 Installation & Operation Manual System piping (continued) Figure 6-6 Double Heater - Double Tank Number of Units Model Required Pipe Sizes 4" 5" 6" 6" 8" 8" 8" 5" 6" 6" 6" 8" 8" 8" 5" 6" 6" 8" 8" 8"...
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Page 36: Gas Connections
Installation & Operation Manual Gas connections Connecting gas supply piping 3. Support piping with hangers, not by the water heater or its accessories. 1. Refer to FIG. 7-1 to pipe gas to the water heater. The gas valve and blower will not support Install ground joint union for servicing, when WARNING the weight of the piping. -
Page 37: Natural Gas
Installation & Operation Manual Gas connections (continued) Natural gas supply pressure requirements Use two wrenches when tightening WARNING gas piping at water heater (FIG. 7-2), 1. Pressure required at the gas valve inlet pressure port: using one wrench to prevent the •... -
Page 38: Check Inlet Gas Supply
Installation & Operation Manual Gas connections Table 7A Natural Gas Pipe Size Chart Capacity of Schedule 40 Metallic Pipe in Cubic Feet of Natural Gas Per Hour (based on .60 specific gravity, 0.30" w.c. pressure drop) Pipe Length of Pipe in Straight Feet Size (Inches) 1 1/4... -
Page 39: Gas Pressure
Installation & Operation Manual Gas connections (continued) Gas Pressure Do not check for gas leaks with an open WARNING flame -- use the bubble test. Failure to The gas pressure must remain between 4 inches w.c. use the bubble test or check for gas leaks (.99 kPa) minimum (5 inches w.c. -
Page 40: Field Wiring
Installation & Operation Manual Field wiring Installation must comply with: ELECTRICAL SHOCK HAZARD – For WARNING your safety, turn off electrical power supply 1. National Electrical Code and any other national, state, before making any electrical connections to avoid possible electric shock hazard. provincial, or local codes, or regulations. -
Page 41: Low Voltage Connections
Installation & Operation Manual Field wiring (continued) Wiring of the cascade Low voltage connections When wiring the water heaters for Cascade operation, select 1. Route all low voltage wires through the knockouts in the one water heater as the Leader water heater. The remaining rear of the water heater, as shown in FIG. - Page 42 Installation & Operation Manual Field wiring Tank sensor Water heater Building Management System (BMS) 1. A tank sensor is required unless the heater is being given a firing rate through the 0 - 10V BMS input or through 1. An external control may be connected to control either ModBus.
- Page 43 Installation & Operation Manual Field wiring (continued) Figure 8-3 Low Voltage Field Wiring Connections MODBUS CASCADE...
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Page 44: Condensate Disposal
Installation & Operation Manual Condensate disposal Condensate drain Use materials approved by the authority NOTICE having jurisdiction. In the absence of other 1. This water heater is a high efficiency appliance that authority, PVC and CPVC pipe must produces condensate. comply with ASTM D1785 or D2845. -
Page 45: 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 46: Final Checks Before Starting The Water Heater
Installation & Operation Manual Start-up Final checks before starting the water Check system and water heater heater Check water piping Read the Armor X2 Water Heater Service Manual to 1. Check system piping for leaks. If found, shut down the familiarize yourself with SMART SYSTEM control water heater and repair immediately. -
Page 47: For Your Safety Read Before Operating
Installation & Operation Manual Start-up (continued) Figure 10-2 Operating Instructions FOR YOUR SAFETY READ BEFORE OPERATING WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury, or loss of life. •... - Page 48 Installation & Operation Manual Start-up Check flame and combustion Set heating operation (continued) 4. Navigate to the Service Mode Screen from the Status Set hot water set point temperature Screen by pressing the MAIN button and then the SERVICE MODE button. During normal operation, hot water set point temperatures can be adjusted from the Set Points Menu.
- Page 49 Installation & Operation Manual Start-up (continued) Set clock Configuration of the cascade To program the clock, access the night setback parameter by When installed in a Cascade system, the individual controls pressing the following buttons: must be programmed for cascade operation. To program the cascade parameters, access the Cascade Menu found in the >>...
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Page 50: Operating Information
Installation & Operation Manual Operating information General How the appliance operates HW pump control When a HW call for heat starts, the appropriate HW pump is The Armor X2 uses advanced stainless steel heat exchangers turned on. and electronic control modules that allow fully condensing operation. -
Page 51: Protection Features
Installation & Operation Manual Operating information (continued) Protection features Monitor external limits Connections are provided on the connection board for Outlet temperature, flue temperature, and temperature external limits. The SMART TOUCH control will shut off rise limiting the burner and inhibit relighting whenever any of these external limits open. -
Page 52: Cascade
Installation & Operation Manual Operating information High limit operations If the set point still cannot be met, the Leader will continue firing more Members until either the heat demand is met or all When outlet temperature exceeds 200°F (93.3°C), high limit units on the Cascade are firing. -
Page 53: Sequence Of Operation
Installation & Operation Manual Operating information (continued) Sequence of operation Note: This unit is equipped with two (2) independent, but synchronized combustion systems. The Heat Exchanger 1 combustion system 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 Heat Exchanger 2 combustion system online. -
Page 54: Armor X2 Water Heater Control Module
Installation & Operation Manual Operating information Armor X2 control module The Status Screen displays water heater status, Cascade addresses, outlet water temperature, inlet water temperature, and tank temperature. The water heater can be forced off by pressing the ON/OFF button. The Details Screen and Main Menu Screen can be accessed by pressing the appropriate button. - Page 55 Installation & Operation Manual Operating information (continued) Hot Water Tank Temperature - This is the temperature as Configuration - This line shows the current configuration of measured by the tank sensor in the hot water storage tank. the two control modules inside the unit. Time - The time is displayed in the upper right-hand corner of Outlet Water Temperature - This is a calculated temperature the display.
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Page 56: Main Menu Screen
Installation & Operation Manual Operating information Use the Main Menu Screen (FIG. 11-2) to access the screens necessary to set temperatures, operating conditions, and monitor water heater operation. The Armor X2 is equipped with a SMART TOUCH control system. All menu options are accessed by touching the screen with your finger or a stylus from a PDA. -
Page 57: 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 Daily • Check water heater area necessary;... -
Page 58: Inspect Water Heater Interior
Installation & Operation Manual Maintenance 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 59: Check Water System
Installation & Operation Manual Maintenance (continued) Failure to inspect for the above conditions Following installation, the valve lever must WARNING WARNING and have them repaired can result in be operated AT LEAST ONCE A YEAR to severe personal injury or death. ensure that waterways are clear. -
Page 60: Review With Owner
Installation & Operation Manual Maintenance Perform start-up and checks Review with owner 1. Start water heater and perform checks and tests specified 1. Review this maintenance schedule with the owner. in Section 10 - Start-up. 2. Emphasize the need to perform the maintenance schedule 2. - Page 61 Installation & Operation Manual Maintenance (continued) 11. Close isolation valves on piping to isolate water heater from system. Attach a hose to the water heater drain and flush water heater thoroughly with clean water by using purging valves to allow water to flow through the water make-up line to the water heater.
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Page 62: Handling Ceramic Fiber Materials
Installation & Operation Manual Maintenance Handling ceramic fiber materials REMOVAL OF COMBUSTION CHAMBER LINING The combustion chamber insulation in this appliance contains ceramic fiber material. Ceramic fibers can WARNING 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).”... -
Page 63: Diagrams
Installation & Operation Manual Diagrams Figure 13-1 Ladder Diagram_Part 1 BOX DEPICTS OPTIONAL ITEMS LOW VOLTAGE 120 VAC HIGH VOLTAGE CONTROL CONTROL MODULE 1 MODULE 2 LOUVER RELAY 1 X6-8 X5-7 X5-7 X5-7 LOUVER X5-4 RELAY 2 X5-4 FLAP AIR PRESSURE FLAP AIR PRESSURE VALVE... - Page 64 Installation & Operation Manual Diagrams Figure 13-2 Ladder Diagram_Part 2 BOX DEPICTS OPTIONAL ITEMS LOW VOLTAGE 120 VAC JUNCTION BOX 120VAC NEUTRAL GROUND HIGH VOLTAGE TERMINAL STRIP TERMINAL STRIP JUNCTION BOX N / L2 120V SUPPLY "L" 120V SUPPLY "N" CONTROL MODULE 1 ON / OFF LOUVER...
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Page 65: Wiring Diagram
Installation & Operation Manual Diagrams (continued) Figure 13-3 Wiring Diagram LOW VOLTAGE 120 VAC HIGH VOLTAGE CM 1 PC INTERFACE BOX DEPICTS OPTIONAL ITEMS LOUVER CONTROL CONTACTS MODULE 1 RELAY JUNCTION PC INTERFACE BOARD LOUVER CONNECTION BOARD CM 2 PC X1-3 CN3-16 INTERFACE... - Page 66 Installation & Operation Manual Notes...
- Page 67 Installation & Operation Manual Notes...
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Page 68: Revision Notes
Revision Notes: Revision A (ECO #C09645) initial release. Revision B (ECO #C11435) reflects edits made to the inlet connections on page 4 and called out on the ratings page (page 6). Changed from 2 1/2" inlet connections to 2" inlet connections (R05572).