Lochinvar Armor 100 Series Service Manual
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Lochinvar Armor 100 Series Service Manual

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100332297_2000589045_Rev A
Service Manual
Models: 400 - 1000
Series 100 & 101
WARNING
This manual must only be used by
a qualified heating installer / service
technician. Read all instructions,
including this manual and the Armor
Installation and Operation Manual,
before installing. Perform steps in the
order given. Failure to comply could
LOW LEAD CONTENT
result in severe personal injury, death,
or substantial property damage.
Save this manual for future reference.

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  • Page 1 100332297_2000589045_Rev A Service Manual Models: 400 - 1000 Series 100 & 101 WARNING This manual must only be used by a qualified heating installer / service technician. Read all instructions, including this manual and the Armor Installation and Operation Manual, before installing.

  • Page 2: Table Of Contents

    Contents 2. MAINTENANCE CONTENTS ............... 2 Maintenance and Annual Startup ........ 23-27 Hazard Definitions .............. 2 3. TROUBLESHOOTING PLEASE READ BEFORE PROCEEDING ..... 3 Before Troubleshooting ............ 28 Handling Ceramic Fiber Materials ........3 Check Control Module Fuses .......... 28 When servicing water heater ........

  • Page 3: Please Read Before Proceeding

    Service Manual Please read before proceeding Installer – Read all instructions, When calling or writing about the water heater WARNING NOTICE including this manual and the Armor – Please have the water heater model and serial number from the water heater rating plate. Water Heater Installation and Operation Manual, before installing.

  • Page 4: What Is In This Manual

    Service Manual What is in this manual? Service Maintenance • Service and maintenance schedules The Armor water heater display • Address reported problems • Inspect water heater area and water heater interior • Display panel readout, buttons and their functions •...

  • Page 5: Service

    Service Manual Service The Armor water heater display HOME VIEW SETUP INFORMATION SETTINGS...

  • 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 LOUVER PROVING SWITCH FLAME SENSOR BLOCKED DRAIN SWITCH SMART SYSTEM...

  • Page 7: Control Outputs

    Service Manual Service (continued) Control outputs ALARM BELL LOW VOLTAGE LOUVER RELAY CONNECTION BOARD RUN TIME CONTACTS SEQUENCER / BUILDING MANAGEMENT SYSTEM BUILDING RECIRCULATION PUMP WATER HEATER PUMP IGNITOR BLOWER SMART SYSTEM GAS VALVE CONTROL BOARD DISPLAY PANEL...

  • Page 8: General Operation

    Service Manual Service General Operation How the water heater operates The Armor water heater uses an advanced stainless steel heat exchanger and an electronic control module that allows fully condensing operation. The blower pulls in gas and air and pushes flue products out of the water heater through the heat exchanger and flue piping.

  • Page 9: Sequence Of Operation

    Service Manual Service (continued) Table 1A Sequence of operation Upon a call for heat, the control turns on the DHW pump. The control confirms that the low water cutoff / flow switch contacts are closed and energizes the louvers (optional). The control confirms that the gas pressure switch, blocked drain switch, limits, louver proving switch (optional), and contacts close.

  • Page 10: Display Panel Menu Access

    Service Manual Service Display panel menu access...

  • Page 11: Parameter Table

    Service Manual Service Parameter table Table 1B This table lists SMART TOUCH control module parameters and where to access them User Access Installer Access Menu Description Display Modify Display Modify Time and Date Software Version (read only) Temperature Units (ºC/ºF) DHW Night Setback Offset DHW Night Setback On Times DHW Night Setback Off Times...
  • Page 12 Service Manual Service (continued) Parameter table Table 1B (continued from previous page) This table lists SMART TOUCH control module parameters and where to access them User Access Installer Access Menu Description Display Modify Display Modify BMS Tstat Input ModBus ModBus T/O Cascade Address Cascade Type Max Cascade Set Point...

  • Page 13: Initial Setup

    (4) hours. This parameter must be accessed to set the clock. If the unit is connected to the internet, the Press the SETTINGS button under the Lochinvar logo time will adjust based on the time zone selected.

  • Page 14: Viewable And Changeable Control Parameters

    Service Manual Service Viewable and changeable control parameters Before changing parameters, note the settings so that the unit can be returned to its original operating CAUTION parameters. Set Point Screens Figure 1-2 Set Points HW Screen...
  • Page 15 Service Manual Service Figure 1-3 HW Night Setback Domestic Hot Water (DHW) Night Setback On and Off Times This is the time in which the Night Setback Offset becomes active. There are 7 start times and 7 stop times each for the DHW night setback feature.
  • Page 16 Service Manual Service (continued) Display Timeout Tank Set Point Offset The tank set point offset measures how far the actual temperature This is the time in which the display remains illuminated. The must go above the set point before the call for heat ends (the range is 10 seconds to 10 minutes.
  • Page 17 Service Manual Service Anti-Cycling Ramp Delay (Enable / Disable) Anti-Cycling Time This parameter allows the installer to enable or disable the DHW ramp delay. The default setting is disabled. Once a DHW demand has been satisfied, a set amount of time Ramp Settings must elapse before the control will respond to a new DHW demand.
  • Page 18 Service Manual Service (continued) Cascade Type Control modes There are two (2) options for the way a Cascade divides the BMS Thermostat Input load between its heaters. The first is Lead/Lag, designated as L/L in the menu. This method is used when it is desired to When controlling the water heater through the 0 - 10V BMS have the least amount of total flow through the water heaters.
  • Page 19 Service Manual Service Maximum Cascade Set Point Minimum Next On Time This parameter determines the set point used by the individual In order to reduce the risk of temperature overshoot with a water heaters in a Cascade. When a water heater is commanded Cascade, this parameter defines the minimum time delay from to fire by the Leader water heater, it will attempt to achieve starting one unit until the next unit may be started.
  • Page 20 Service Manual Service Figure 1-6 Cascade Leader Setup Figure 1-7 Cascade Member Size Screen...
  • Page 21 Service Manual Service Circulation pumps Set Point at Minimum Volts When programmed for BMS control through the 0 - 10V DHW Pump Delay BMS input or through ModBus and the BMS Type is The DHW pump delay parameter sets the length of time the programmed as SETPOINT, the set point represented by DHW pump (if connected) will run after a DHW demand has the Volts at Minimum parameter is set by the Set Point at...
  • Page 22 Service Manual Service (continued) Figure 1-8 Service Notification Screen Table 1I Service Notification (This table lists control module parameters; use the sub-tab under the Setup tab to access them. Default Parameter Name Menu (as shown on the LCD screen) Value Value Value Maintenance Notice By: Months...

  • Page 23: Maintenance

    Service Manual Maintenance Maintenance and annual startup Table 2A 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; • Check water heater area •...
  • Page 24 Service 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 25 Service Manual Maintenance Flue vent system and air piping Safety relief valves should be re-inspected WARNING AT LEAST ONCE EVERY THREE YEARS, Visually inspect the entire flue gas venting system and air by a licensed plumbing contractor or piping for blockage, deterioration or leakage. Repair any authorized inspection agency, to ensure joints that show signs of leakage.
  • Page 26 Service Manual Maintenance Maintenance (continued) Inspect ignition and flame sense Check burner flame electrodes 1. Inspect flame through observation window. 1. Remove the ignition and flame sense electrodes from 2. If the flame is unsatisfactory at either high fire or low fire, the water heater heat exchanger access cover.
  • Page 27 Service Manual Table 2B Heat Exchanger Cleaning Kits Maintenance Part Component Cleaning heat exchanger Model Number Number Description For recommended materials; including brush, appropriate Rear Refractory Cover, 100333410 extension(s), refractory cover, and detailed instructions see 10.75" Diameter Table 2B - Heat Exchanger Cleaning Kits. Rear Refractory Cover, 100208804 1.

  • Page 28: Troubleshooting

    Service Manual Troubleshooting Label all wires prior to disconnection Check control module fuses WARNING when servicing controls. Wiring errors can cause improper and ALWAYS check control module fuses before NOTICE dangerous operation. Always replacing control module or any major disconnect power to the water heater components (blower, etc.).
  • Page 29 Service Manual Troubleshooting Table 3A Troubleshooting Chart - No Display FAULT CAUSE CORRECTIVE ACTION • Check external line switch, fuse, or breaker. • Check position of ON/OFF switch. Turn switch to the ON position. - No 120 VAC supplied to unit. •...

  • Page 30: Checking Temperature Sensors

    Service Manual Troubleshooting (continued) 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 31 Service Manual Troubleshooting Table 3E Troubleshooting Chart - Noisy System FAULT CAUSE CORRECTIVE ACTION - Supply gas problem. Natural gas pressures • Refer to the Gas Connections section of the Armor should be between 4 inches w.c. and 14 Water Heater Installation and Operation Manual for inches w.c.
  • Page 32 Service Manual Troubleshooting (continued) Table 3F Troubleshooting Chart - Fault Messages Displayed on Water Heater Interface FAULT DESCRIPTION CORRECTIVE ACTION • Reset the pressure switches. • Measure the supply gas pressure to determine cause Gas Pressure SW of failure. Natural gas pressures should be between (will require a manual 4 - 14 inches w.c.
  • Page 33 Service Manual Troubleshooting Table 3F (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Water Heater Interface FAULT DESCRIPTION CORRECTIVE ACTION The main control board has received a call • The control board will release the call for heat after a Anti-cycling for heat too quickly after the previous call for set time period.
  • Page 34 Service Manual Troubleshooting (continued) Table 3F (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Water Heater Interface FAULT DESCRIPTION CORRECTIVE ACTION • Check wiring harness connection at the gas valve and at the main control board. • Inspect spark electrode and associated wiring for damage and connection.
  • Page 35 Service Manual Troubleshooting Table 3F (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Water Heater Interface FAULT DESCRIPTION CORRECTIVE ACTION Flame Sequence • Check supply voltage for proper polarity. (will require a manual • Check external wiring for voltage feedback. reset once the condition The flame detector circuit is seeing a flame •...
  • Page 36 Service Manual Troubleshooting (continued) Table 3F (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Water Heater Interface FAULT DESCRIPTION CORRECTIVE ACTION • Vent/air intake lengths exceed the maximum allowed lengths. Refer to the General Venting section of the Armor Water Heater Installation and Operation Fan Low Manual for proper lengths.
  • Page 37 Service Manual Troubleshooting Table 3F (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Water Heater Interface FAULT DESCRIPTION CORRECTIVE ACTION Sensor Shorted • Check the sensors and their associated wiring. Repair or replace the sensor or wiring if damaged. (will require a manual Either the inlet water or outlet water reset once the condition...
  • Page 38 Service Manual Troubleshooting (continued) Table 3F (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Water Heater Interface FAULT DESCRIPTION CORRECTIVE ACTION • Verify that the system is full of water and that all air has been properly purged from the system. •...
  • Page 39 Service Manual Troubleshooting Table 3F (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Water Heater Interface FAULT DESCRIPTION CORRECTIVE ACTION 120 VAC input to the main control board has • Check 120 VAC supply to the transformer. dropped below 80 VAC.

  • Page 40: Combustion Analysis Procedure

    Service Manual Troubleshooting (continued) Check flame and combustion 7. Once the water heater has modulated up to full fire, measure the combustion. The values should be in the range 1. Turn the main power off to the water heater by placing the listed in Table 3G below.

  • Page 41: Gas Valve Adjustment Procedure

    Service Manual Troubleshooting Gas valve adjustment procedure 1. For Models 400-500: Remove the front panel from the unit (no tools required for removal). For Models 650-1000: Remove the top access cover from the unit (no tools required for removal). 2. For Models 650-1000: Remove the cover on top of the gas valve (FIG.
  • Page 42 Service Manual NOTES...
  • Page 43 Service Manual NOTES...
  • Page 44 Revision Notes: Revision A (PCP #3000042688 / CN #500030426) ARM-SER-01 initial release. CP-2M-01/06 100332297_2000589045_Rev A 11/20...

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