Lochinvar 151 - 801 Operation Manual

Lochinvar 151 - 801 Operation Manual

Armor outdoor armor water heater
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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.
Outdoor Armor Water
Heater Installation &
Operation Manual
Models: 151 - 801
This manual must only be used by
WARNING
a qualified heating installer / service
technician. Read all instructions,
including this manual and the
Outdoor Armor 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.
OAW-I-O Rev D

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Summary of Contents for Lochinvar 151 - 801

  • Page 1 OAW-I-O Rev D Outdoor Armor Water Heater Installation & Operation Manual Models: 151 - 801 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.
  • Page 2: Table Of Contents

    Contents HAZARD DEFINITIONS ............ 2 4. GAS CONNECTIONS PLEASE READ BEFORE PROCEEDING ......3 Connecting Gas Supply Piping ........21 THE OUTDOOR ARMOR WATER HEATER -- HOW IT Natural Gas ..............22 WORKS ................4-6 Pipe Sizing for Natural Gas ........22 RATINGS ................
  • Page 3: Please Read Before Proceeding

    Outdoor Armor Water Heater Installation & Operation Manual Please read before proceeding When servicing the water heater – Installer – Read all instructions, including WARNING this manual and the Outdoor Armor Water • To avoid electric shock, disconnect electrical supply Heater Service Manual, before installing.
  • Page 4: The Outdoor Armor Water Heater -- How It

    Outdoor Armor Water Heater Installation & Operation Manual The Outdoor Armor Water Heater - How it works... Stainless steel heat exchanger 20. Low voltage wiring connections (plugs) Allows water to flow through specially designed coils for maximum Conduit connection points for the low voltage connection heat transfer, while providing protection against flue gas corrosion.
  • Page 5: Works

    Outdoor Armor Water Heater Installation & Operation Manual The Outdoor Armor Water Heater - How it works... (continued) Models 151 - 200 IMG00284 IMG00287 Rear View - Models 151 - 200 Left Side (inside unit) - Models 151 - 200 IMG00359 IMG00360 Left Side (inside unit) - Model 286...
  • Page 6 Outdoor Armor Water Heater Installation & Operation Manual The Outdoor Armor Water Heater - How it works... Models 400 - 501 IMG00396 IMG00395 Left Side (inside unit) - Models 400 - 501 Rear View - Models 400 - 501 Models 601 - 801 IMG00288 IMG00289 Left Side (inside unit) - Models 601 - 801...
  • Page 7: Ratings

    Outdoor Armor Water Heater Installation & Operation Manual Ratings Model Number Input Modulation Btu/hr Water Content Water Note: Change “N” Gallons Connections Connections to “L” for L.P. gas models. (Note 2) OAN151PM 30,000 - 150,000 1-1/4" 1/2" OAN200PM 40,000 - 199,999 1-1/4"...
  • Page 8: Determine Water Heater Location

    Outdoor Armor Water Heater Installation & Operation Manual Determine water heater location Installation must comply with: • Local, state, provincial, and national codes, laws, regulations, 2. - Keep venting areas free of obstructions. and ordinances. - Keep area clean and free of combustible and flammable materials.
  • Page 9: Provide Clearances

    Outdoor Armor Water Heater Installation & Operation Manual Determine water heater location (continued) Flooring and foundation 3. Check area around the water heater. Remove any combustible materials, gasoline and other flammable Flooring liquids. The outdoor Armor water heater is approved for installation on Failure to keep the water heater area clear combustible flooring.
  • Page 10: Prepare Water Heater

    Outdoor Armor Water Heater Installation & Operation Manual Prepare water heater Remove water heater from wood pallet Figure 2-2 Install Flue Pipe Assembly - Models 151 - 601 WALL STRAP SCREWS 1. After removing the outer shipping carton from the water BIRD SCREEN WALL STRAP heater, remove the installation kit.
  • Page 11: Gas Conversions

    Outdoor Armor Water Heater Installation & Operation Manual Prepare water heater (continued) Gas conversions Figure 2-4 Installing Propane Orifice - Models 151 - 286 For a water heater already installed, you WARNING must turn off gas supply, turn off power and allow the water heater to cool before proceeding.
  • Page 12: Leveling The Water Heater

    Outdoor Armor Water Heater Installation & Operation Manual Prepare water heater Figure 2-5 Installing Propane Orifice - Model 400 4. Use a combustion analyzer to verify CO is within the range of 9.6 – 10.5%. If not, adjust the screw counterclockwise incrementally to raise CO and clockwise to lower CO (FIG.
  • Page 13: System Piping

    Outdoor Armor Water Heater Installation & Operation Manual System piping System water piping methods Figure 3-1 Pump Cover Installation - Models 151 - 286 Observe a minimum of 1/4 inch clearance around all SCREWS (10X) un-insulated hot water pipes when openings around the pipes are not protected by non-combustible materials.
  • Page 14: Flow Switch Adjustment

    Installation & Operation Manual System piping Turn the sensitivity screw clockwise to increase Attach the paddle to the flow switch per the manufacturer’s NOTICE the flow rate required to activate the switch. instructions. Reference Table 3A to select the Turn the sensitivity screw counterclockwise to correct paddle for the pipe size used (consult the decrease the flow rate required to activate the manufacturer’s instructions for a detailed explanation).
  • Page 15: Water Chemistry

    Tank sensor: specifications. Lochinvar supplies a tank sensor. The tank sensor must be Heating of high hardness and/or high total dissolved solids installed in the tapping provided in the lower 25% of the storage water may require a larger circulating pump, and a revised tank to achieve proper operation.
  • Page 16 Installation & Operation Manual System piping Figure 3-6 Single Heater - Single Tank BUILDING FLOW CHECK RETURN VALVE (TYPICAL) BALL VALVE (TYPICAL) COLD WATER WATER SUPPLY HEATER CIRCULATOR MIXING VALVE WATER HEATER THERMOMETER HOT WATER SUPPLY UNION (TYPICAL) TEMPERATURE & PRESSURE RELIEF VALVE FLOW SWITCH STORAGE...
  • Page 17 Installation & Operation Manual System piping (continued) Figure 3-7 Single Heater - Single Tank (2 Temperature) FLOW CHECK VALVE (TYPICAL) 180° HOT HIGH TEMPERATURE THERMOMETER WATER BUILDING RETURN (TYPICAL) SUPPLY UNION BALL VALVE 140° HOT (TYPICAL) (TYPICAL) MIXING WATER VALVE TEMPERATURE WATER HEATER SUPPLY...
  • Page 18 Outdoor Armor Water Heater Installation & Operation Manual System piping Figure 3-8 Single Heater - Double Tank BALL VALVE (TYPICAL) BUILDING FLOW CHECK RETURN VALVE (TYPICAL) EXPANSION TANK COLD WATER SUPPLY WATER HEATER CIRCULATOR MIXING VALVE FLOW SWITCH THERMOMETER HOT WATER SUPPLY UNION (TYPICAL)
  • Page 19 Outdoor Armor Water Heater Installation & Operation Manual System piping (continued) Figure 3-9 Double Heater - Single Tank Number of Units Model Required Pipe Sizes in NPT 1 1/2" 2" 2" 2" 2 1/2" 3" 3" 1 1/2" 2" 2 1/2" 2 1/2" 3"...
  • Page 20 Outdoor Armor Water Heater Installation & Operation Manual System piping Figure 3-10 Double Heater - Double Tank Number of Units Model Required Pipe Sizes in NPT 1 1/2" 2" 2" 2" 2 1/2" 3" 3" 1 1/2" 2" 2 1/2" 2 1/2" 3"...
  • Page 21: Gas Connections

    Outdoor Armor Water Heater Installation & Operation Manual Gas connections Connecting gas supply piping Figure 4-3 Gas Supply Piping - Model 501 UNION (FACTORY INSTALLED) 1. Remove the top access panel and refer to FIG.’s 4-1 thru 4-4 GAS SUPPLY to pipe gas to the water heater.
  • Page 22: Natural Gas

    Outdoor Armor Water Heater Installation & Operation Manual Gas connections Natural gas: Do not check for gas leaks with an open WARNING flame – use the bubble test. Failure to use Pipe sizing for natural gas the bubble test or check for gas leaks can cause severe personal injury, death, or 1.
  • Page 23: Check Inlet Gas Supply

    Outdoor Armor Water Heater Installation & Operation Manual Gas connections (continued) Table 4A Natural Gas Pipe Size Chart Single Unit Nominal Natural Gas Pipe Capacity Chart Iron Pipe Length of Pipe in Straight Feet for 1/2 PSI Size (Inches) 1-1/4 1400 1-1/2 2150...
  • Page 24: Gas Pressure

    Outdoor Armor Water Heater Installation & Operation Manual Gas connections 17. Check burner performance by cycling the system while Figure 4-9 Inlet Gas Supply Check - Models 601 - 801 you observe burner response. The burner should ignite promptly. Flame pattern should be stable. Turn system REMOVE THE 1/8”...
  • Page 25: Field Wiring

    Outdoor Armor Water Heater Installation & Operation Manual Field wiring Installation must comply with: ELECTRICAL SHOCK HAZARD – For WARNING your safety, turn off electrical power supply before making any electrical connections 1. National Electrical Code and any other national, state, to avoid possible electric shock hazard.
  • Page 26: Flow Switch

    Outdoor Armor Water Heater Installation & Operation Manual Field wiring Tank thermostat Flow switch 1. Connect the tank thermostats (isolated contact only) to 1. A flow switch is used to guarantee flow through the water the tank thermostat contacts as shown in FIG. 5-3. heater before allowing it to fire.
  • Page 27: Runtime Contacts

    Outdoor Armor Water Heater Installation & Operation Manual Field wiring (continued) Runtime contacts The SMART SYSTEM control closes a set of dry contacts whenever the burner is running. This is typically used by Building Management Systems to verify that the water heater is responding to a call for heat.
  • Page 28 Outdoor Armor Water Heater Installation & Operation Manual Field wiring Figure 5-3 Low Voltage Field Wiring Connections...
  • Page 29: Condensate Disposal

    Outdoor Armor Water Heater Installation & Operation Manual Condensate disposal Condensate drain Use materials approved by the authority NOTICE having jurisdiction. In the absence of other authority, PVC and CPVC pipe must comply 1. This water heater is a high efficiency appliance that with ASTM D1785 or D2845.
  • Page 30: Startup

    Outdoor Armor Water Heater 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.
  • Page 31: Final Checks Before Starting The Water Heater

    Outdoor Armor Water Heater Installation & Operation Manual Start-up (continued) Final checks before starting the water  Check vent piping and air piping heater 1. Check for gastight seal at every connection, seam of air  Read the Outdoor Armor Water Heater Service Manual piping, and vent piping.
  • Page 32: For Your Safety Read Before Operating

    Outdoor Armor Water Heater Installation & Operation Manual Start-up Figure 7-2 Operating Instructions - Models 151 - 286 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. A.
  • Page 33 Outdoor Armor Water Heater Installation & Operation Manual Start-up (continued) Figure 7-3 Operating Instructions - Models 400 - 801...
  • Page 34 Outdoor Armor Water Heater Installation & Operation Manual Start-up Check flame and combustion Set water heater operation (continued) 4. Place the water heater into the active position by pressing Set tank set point temperature the RIGHT SELECT [ON] key (FIG. 8-1, page 40). Please note that the brackets ([]) denote NOTICE screen status.
  • Page 35 Outdoor Armor Water Heater Installation & Operation Manual Start-up (continued) Configuration of the cascade Set clock Please note that the brackets ([]) denote Please note that the brackets ([]) denote NOTICE NOTICE screen status. screen status. The SMART SYSTEM control has a built-in clock that it When installed in a Cascade system, the individual controls uses for its night setback feature and for logging events.
  • Page 36: Operating Information

    Outdoor Armor Water Heater Installation & Operation Manual Operating information General Protection features How the water heater operates Outlet temperature, flue temperature, and temperature rise limiting The outdoor water heater uses an advanced stainless steel heat The outlet temperature is monitored by the water heater outlet exchanger and electronic control module that allows fully temperature sensor.
  • Page 37: Water Heater Temperature Regulation

    Outdoor Armor Water Heater Installation & Operation Manual Operating information (continued) Monitor external limits When the outlet temperature exceeds 200°F, the automatic high limit action occurs. The water heater shuts down until the outlet Connections are provided on the connection board for water temperature cools below 190°F, and a 60 second timer has external limits such as a flow switch and gas pressure expired.
  • Page 38: Cascade

    Outdoor Armor Water Heater Installation & Operation Manual Operating information Cascade Access modes When multiple water heaters are installed, they can be User wired together in a cascade sequence. A maximum of eight water heaters can be controlled from a single control. In The user can adjust tank target temperatures by pressing the this application one water heater would be designated as the NAVIGATION dial when “SETPOINTS”...
  • Page 39: Sequence Of Operation

    Outdoor Armor Water Heater Installation & Operation Manual Operating information (continued) Sequence of operation OPERATION DISPLAY 1. The control will turn on the water heater pump (always ON except in Night Setback). The flow switch and/or LWCO must close. 2. Air pressure switch and blocked drain switch must close. 3.
  • Page 40: Outdoor Armor Water Heater Control Module

    Outdoor Armor Water Heater Installation & Operation Manual Operating information Outdoor Armor water heater control module Use the control panel (FIG. 8-1) to set temperatures, operating conditions, and monitor water heater operation. Figure 8-1 Control Panel The information on the bottom of the display shows the functions of the two SELECT keys (on either corner), and the NAVIGATION dial (in the center): MENU = Left SELECT Key SETPOINTS = NAVIGATION Dial - Pressing Down...
  • Page 41: Status Display Screens

    Outdoor Armor Water Heater Installation & Operation Manual Operating information (continued) Figure 8-2 Status Display Screen Status Display Screens Section Display Description The unit has not received a call for heat from a remote thermostat nor STANDBY has it received a call for heat from a DHW thermostat. START The unit has begun a burn cycle and is checking all safety circuits.
  • Page 42: Status Display Screens

    Outdoor Armor Water Heater Installation & Operation Manual Operating information Status Display Screens (cont’d) Section Display Description TANK: The temperature read by the tank sensor (if connected). INLET TEMP: The temperature read at the inlet to the heat exchanger. OUTLET TEMP: The temperature read at the outlet of the heat exchanger.
  • Page 43 Outdoor Armor Water Heater Installation & Operation Manual Operating information (continued) Status Display Screens (cont’d) Section Display Description Turning the NAVIGATION dial will select the next or previous Status Screen. Pressing the NAVIGATION dial will show the next fault, NSB (Night Setback) trigger, or ramp delay setting.
  • Page 44: Maintenance

    Outdoor Armor Water Heater Installation & Operation Manual Maintenance Maintenance and annual startup Table 9A 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 •...
  • Page 45: Address Reported Problems

    Outdoor Armor Water Heater Installation & Operation 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.
  • Page 46: Check Water System

    Outdoor Armor Water Heater Installation & Operation Manual Maintenance 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 47: Check Burner Flame

    Outdoor Armor Water Heater Installation & Operation Manual Maintenance (continued) Perform start-up and checks 3. Remind the owner to follow the proper shutdown procedure and to schedule an annual start-up. 1. Start water heater and perform checks and tests specified Cleaning heat exchanger in Section 7 - Start-up.
  • Page 48: Check Delta T

    Outdoor Armor Water Heater Installation & Operation Manual Maintenance Check Delta T Table 9B Heat Exchanger Cleaning Kits 1. Check Delta T. Reference Section 3 - System Piping on Part Component page 15 for more information regarding Delta T. Model Number Number Description...
  • Page 49: Diagrams

    Outdoor Armor Water Heater Installation & Operation Manual Diagrams Figure 10-1 Ladder Diagram JUNCTION BOX 120VAC NEUTRAL GROUND TERMINAL STRIP TERMINAL STRIP 120V SUPPLY "L" 120V SUPPLY "N" AW MODELS ONLY INTEGRATED CONTROL ON / OFF SWITCH X1-1 BLOWER 3.15A X1-6 X1-2 BUILDING...
  • Page 50: Wiring Diagram

    Outdoor Armor Water Heater Installation & Operation Manual Diagrams Figure 10-2 Wiring Diagram LOW VOLTAGE BOX DEPICTS 120 VAC OPTIONAL ITEMS HIGH VOLTAGE BOX DEPICTS DUAL SENSOR SINGLE HOUSING INTEGRATED CONNECTION BOARD CONTROL JUNCTION ALARM X1-3 OR/BK CONTACTS RUN-TIME PUMP CONTACTS X1-4 24 VAC LOUVER...
  • Page 51 Installation & Operation Manual OUTDOOR CONDENSING WATER HEATER Notes...
  • Page 52: Revision Notes

    Revision Notes: Revision A (ECO #C10942) initial release. Revision B (ECO #C11235) reflects updates made to the freezing conditions warnings. Revision C (ECO C12102) reflects the addition of condensate kit option information for areas that may reach below 32°F as well as a warning not to install OA 400 in these areas and Table 1A on page 8.

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