Lochinvar Armor 150 - 500 Service Manual
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Lochinvar Armor 150 - 500 Service Manual

Lochinvar condensing water heater service manual
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AW-SER Rev E
Service 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
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.
Save this manual for future reference.

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Summary of Contents for Lochinvar Armor 150 - 500

  • Page 1 AW-SER Rev E Service 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 Installation Operation Manual, before installing. Perform steps in the order given.

  • Page 2: Table Of Contents

    When servicing water heater ....3 Water heater operation ......3 WHAT IS IN THIS MANUAL .

  • Page 3: Please Read Before Proceeding

    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. thoroughly.

  • Page 4: What Is In This Manual

    • J: 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 •...

  • Page 5: Service

    Service Manual Service The Armor water heater display...

  • Page 6: Control Inputs

    Service Manual Service Control inputs GAS PRESSURE SWITCH DHW THERMOSTAT LOW VOLTAGE FLOW SWITCH CONNECTION BOARD TANK SENSOR SEQUENCER / BUILDING MANAGEMENT SYSTEM LOW WATER CUTOFF INLET TEMPERATURE SENSOR OUTLET TEMPERATURE SENSOR FLUE GAS SENSOR AIR PRESSURE SWITCH HIGH LIMIT SENSOR FLAME SENSOR BLOCKED DRAIN SWITCH SMART SYSTEM...

  • Page 7: Control Outputs

    Service (continued) Control outputs LOW VOLTAGE CONNECTION BOARD SMART SYSTEM CONTROL BOARD Service Manual ALARM BELL AUX. DEVICE RELAY RUNTIME CONTACTS SEQUENCER / BUILDING MANAGEMENT SYSTEM DHW PUMP IGNITER BLOWER GAS VALVE DISPLAY PANEL PC INTERFACE...

  • Page 8: General Operation

    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.

  • Page 9: Sequence Of Operation

    Sequence of operation Table 1A Sequence of operation OPERATION 1. Upon a call for heat, the control turns on the water heater pump. 2. The control connects 120 VAC to the blower. The blower does not run at this time.

  • Page 10: Display Panel Menu Access

    To select a highlighted menu, press the ENTER/RESET button one time. The display will change to the first parameter under that menu, with the first characters flashing. DISPLAY COMMENTS Water heater turns off (this ensures WHR:OFF uninterrupted programming) OUT:125˚F Digit shown underlined at left will...

  • Page 11: Display Panel Parameter Access

    Service (continued) Display panel parameter access Table 1C This is a typical example of accessing a parameter, shown for parameter H3, cascade address BUTTON OPERATION This example shows how to access parameter H3, cascade address. The first display shown is at the beginning of the menu listings, after entering the installer access code.

  • Page 12: Parameter Table

    Service Parameter table Table 1D This table lists SMART SYSTEM control module parameters and where to access them MENU SUB ITEM Boiler Model User Code Date and Time Software Version Temperature Units Night Setback Temperature Night Setback Times Total Hrs. Run Ignition Attempts Show Last 10 Errors Reset Last 10 Errors...

  • Page 13: Viewable And Changeable Control Parameters

    The control uses an internal clock for the night setback feature and for logging of events. For these features to work correctly, the clock must be set when the water heater is first installed or anytime the water heater has been powered off for more than 30 days.
  • Page 14 The delay sets the length of time the water heater will stay in the Service Mode if no keys have been pressed before going back to its original state.
  • Page 15 Service notification in months When the water heater control determines that a scheduled service is due based on days of installation, the water heater display will alternate the standard water heater display text with the message SERVICE DUE every 5 seconds. This parameter is adjustable by the installer by accessing parameter J1.

  • Page 16: Maintenance

    • Check vent piping • Check air piping • Check air and vent termination screens • Check relief valve • Check condensate drain system • Check automatic air vents • Check water heater piping (gas and water) for leaks • Operate relief valve...

  • Page 17: Address Reported Problems

    Failure to service and maintain the water heater and system could result in equipment failure. Electrical shock hazard – Turn off power to the water heater before any service operation on the water heater WARNING except as noted otherwise in this instruction manual.

  • Page 18: Check Water System

    2. Check the cold fill pressure for the system. Verify it is correct (must be a minimum of 12 PSI). 3. Watch the system pressure as the water heater heats up (during testing) to ensure pressure does not rise too high.

  • Page 19: Check Ignition Ground Wiring

    4. Replace ground wires if ground continuity is not satisfactory. Check all water heater wiring 1. Inspect all water heater wiring, making sure wires are in good condition and securely attached. Check control settings 1. Set the SMART SYSTEM control module display to Parameter Mode and check all settings.

  • Page 20: Check Flame Signal

    • Follow the “To Turn Off Gas to Appliance” instructions for the water heater in the Armor Water Heater Installation and Operation Manual. • Do not drain the water heater unless it will be exposed to freezing temperatures. If using freeze prevention fluid in system, do not drain.

  • Page 21: Troubleshooting

    F2 - 3.15 AMP FUSE 24V SUPPLY 5. The water heater is shipped with three (3) spare fuses in a plastic bag attached to the control module cover. 6. If necessary, replace open fuse (F3 is 1.25 amps, F2 and F4 are 3.15 amps, and F5 is 5 amps).

  • Page 22: Table 3A - Troubleshooting Chart - No Display

    - Main control board temperature set point satisfied. No Burner - Remote thermostat satisfied. Operation - Unit locked out on fault. - Water heater controlled by BMS. Unit Does Not - Flue sensor open. Modulate Above CAUSE • Check external line switch, fuse, or breaker.

  • Page 23: Checking Temperature Sensors

    Checking temperature sensors The water heater temperature sensors (inlet water, outlet water, system water, and flue) are all resistance type devices. The following tables show the correct values for the sensors at various temperatures. Use an ohmmeter to read the resistance of the sensor at a known temperature.

  • Page 24: Table 3D - Troubleshooting Chart - Noisy System

    CAUSE • Refer to Section 7 - Gas Connections of the Armor LP gas pressures should Water Heater Installation and Operation Manual for inches w.c. detailed information concerning the gas supply. • Refer to the Gas Valve Adjustment Procedure on page 33 of this manual for the proper gas valve setting.

  • Page 25: Table 3E - Troubleshooting Chart - Fault Messages

    Troubleshooting Table 3E Troubleshooting Chart - Fault Messages Displayed on Water Heater Interface FAULT DESCRIPTION Either the manual reset low gas pressure switch or the manual reset high gas pressure switch tripped. Gas Pressure SW (will require a manual reset once the condition has been corrected.
  • Page 26 Troubleshooting Table 3E (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Water Heater Interface FAULT DESCRIPTION The unit has failed to prove main burner ignition after four (4) attempts. Exception: The 500 Model will lock out after one (1) try for ignition.

  • Page 27: Corrective Action

    Troubleshooting Table 3E (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Water Heater Interface FAULT DESCRIPTION The unit was running and lost the flame signal. This condition occurred four (4) straight times. Exception: The 500 Model will lock out after one (1) try.
  • Page 28 Troubleshooting Table 3E (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Water Heater Interface FAULT Manual Reset High Limit (will require a manual reset once the condition The outlet water temperature has exceeded has been corrected. Press...
  • Page 29 Troubleshooting Table 3E (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Water Heater Interface FAULT The actual fan RPM is 30% higher than what is being called for. Fan High Fan Speed High (will require a manual reset once the condition has been corrected.
  • Page 30 Troubleshooting Table 3E (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Water Heater Interface FAULT The temperature rise across the heat exchanger has exceeded the set parameters for the water heater. Temp O/Shoot (continued) Outlet water temperature has exceeded the maximum outlet water temperature.
  • Page 31 Troubleshooting Table 3E (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Water Heater Interface FAULT While the unit is in Service Mode, the outlet temperature has exceeded 185°F. Service Blk 120 VAC input to the main control board has dropped below 80 VAC.

  • Page 32: Combustion Analysis Procedure

    Table 3F Troubleshooting Chart - Combustion Levels POSSIBLE CAUSE • Refer to Section 3 - General Venting of the Armor Water Heater Installation and Operation Manual for the proper venting and air intake methods for the Armor water heater. Vent/Air Intake Length or Obstruction •...

  • Page 33: Gas Valve Adjustment Procedure

    Troubleshooting Gas valve adjustment procedure If adjustment of the gas valve is deemed necessary, use the following procedures: (Note: The procedures below are model specific.) Models 150 - 285 Locate the throttle adjustment screw on the side of the venturi valve (FIG.
  • Page 34 NOTES...
  • Page 35 NOTES...

  • Page 36: Revision Notes

    Revision Notes: Revision B (AW-SER-Rev B) reflects the addition of the Dungs information to the manual. Revision C (ECO #C02407) reflects the addition of the air pressure switch, FIG. 3-1, removal of pocket pc references and changes made to the Circulation Pump section (page 15). Revision D (ECO #C02545) reflects the addition of references to periodic cleaning of screens in vent terminations and safety shutoff testing and instructions.

This manual is also suitable for:

Armor 150Armor 500

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