Table of Contents
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AW-SER Rev H
Service Manual
Models: 150 - 800
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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Table of Contents
Troubleshooting
Related Manuals for Lochinvar ARMOR 150 - 800
Summary of Contents for Lochinvar ARMOR 150 - 800
- Page 1 AW-SER Rev H Service Manual Models: 150 - 800 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.
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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 Control inputs GAS PRESSURE SWITCH (OPTIONAL) DHW THERMOSTAT FLOW SWITCH TANK SENSOR SEQUENCER / BUILDING MANAGEMENT SYSTEM LOW WATER CUTOFF (OPTIONAL) INLET TEMPERATURE SENSOR OUTLET TEMPERATURE SENSOR FLUE GAS SENSOR AIR PRESSURE SWITCH HIGH LIMIT SENSOR FLAME SENSOR BLOCKED DRAIN SWITCH DISPLAY PANEL PC INTERFACE (OPTIONAL) -
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.
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Page 16: Maintenance
• Check air and vent termination screens • Check relief valve • Check condensate drain system • Check air vents • Check Delta T (Temperature Rise) • 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
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. -
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
33-34 of this manual for the proper gas valve setting. exceed the maximum listed in the General Venting section of the Armor Water Heater Installation and Operation Manual. • Refer to page 19 in this manual for the burner removal and inspection procedure. -
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: Models 500 - 800 will lock out after one retry for ignition.
- Page 27 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: Models 500 - 800 will lock out after one retry for ignition.
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Page 28: Corrective Action
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.
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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 Troubleshooting Model 500 Locate the throttle adjustment screw on top of the gas valve, see FIG. 3-4. Using a screwdriver, turn the screw a 1/4 turn counterclockwise to increase CO levels or a 1/4 turn clockwise to decrease CO levels. After one adjustment on the valve, follow the Combustion Analysis Procedure on page 32 of this manual to measure the combustion.
- Page 35 NOTES...
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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.