Lochinvar ARMOR 151 Installation And Operation Manual
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Lochinvar ARMOR 151 Installation And Operation Manual

Condensing water heateer
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See also: Service Manual , Instruction Manual
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 Manual
Models: 151 - 801
This manual must only be used
WARNING
by a qualified heating installer
/ service technician. Read all
instructions, including this manual
and the Armor Water Heater Service
Manual, before installing. Perform
steps in the order given.
to comply could result in severe
personal injury, death, or substantial
property damage.
Save this manual for future reference.
AWII-I-O Rev C
Failure

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Summary of Contents for Lochinvar ARMOR 151

  • Page 1 -- This water heater MUST NOT be installed in any location where gasoline or flammable vapors are likely to be present.

  • Page 2: Table Of Contents

    HAZARD DEFINITIONS ... 2 PLEASE READ BEFORE PROCEEDING ... 3 THE ARMOR WATER HEATER -- HOW IT WORKS ... 4-6 RATINGS ... 7 1. DETERMINE WATER HEATER LOCATION Provide Clearances ... 8 Provide Air Openings to Room ... 10 Flooring and Foundation ... 10 Residential Garage Installation ...

  • Page 3: Please Read Before Proceeding

    Instead, shut off the gas supply at a location external to the appliance. • Do not use this water heater if any part has been under water. The possible damage to a flooded appliance can be extensive and present numerous safety hazards. Any...

  • Page 4: The Armor Water Heater - How It Works

    The venturi controls air and gas flow into the burner. Flue gas (limit rated) This sensor monitors the flue gas exit temperature. The control module will modulate and shut down the water heater if the flue gas temperature gets too hot. This protects the flue pipe from overheating.
  • Page 5 The Armor Water Heater - How it works... Models 151 - 200 Rear View - Models 151 - 200 Rear View - Model 286 Left Side (inside unit) - Models 151 - 200 Left Side (inside unit) - Model 286 Installation &...
  • Page 6 The Armor Water Heater - How it works... Models 400 - 501 Rear View - Models 400 - 501 Models 601 - 801 Rear View - Models 601 - 801 Left Side (inside unit) - Models 400 - 501 Left Side (inside unit) - Models 601 - 801...

  • Page 7: Ratings

    2. Standard Armor water heaters are equipped to operate from sea level to 4,500 feet only with no adjustments. The water heater will de-rate by 4% for each 1,000 feet above sea level up to 4,500 feet. 3. High altitude Armor water heaters are equipped to operate from 3,000 to 12,000 feet only with no field adjustments.

  • Page 8: Closet And Alcove Installations

    Closet and alcove installations A closet is any room the water heater is installed in which is less than 86 cubic feet for AWN151 models, 106 cubic feet for AWN200 models, 120 cubic feet for AWN286 models, 165...
  • Page 9 Determine water heater location Figure 1-1 Closet Installation - Minimum Required Clearances 1/4” MINIMUM CLEARANCE AROUND HOT WATER PIPES 1” MINIMUM CLEARANCE AROUND VENT PIPES 12” LEFT 14” REAR Figure 1-2 Alcove Installation - Minimum Required Clearances 1/4” MINIMUM CLEARANCE AROUND HOT WATER PIPES 1”...

  • Page 10: Provide Air Openings To Room

    Do not attempt to install the Armor water heater using any other means. Be sure to locate the water heater such that the vent and air piping can be routed through the building and properly terminated.

  • Page 11: Corrosive Contaminants And Sources

    • Seal - With prior requirements met, the system should be tested to the procedure listed in parts (c) through (f) of the Removal of an Existing Water Heater Section on page 12. With stainless steel vent, seal and connect all pipe and components as specified by the vent manufacturer used;...

  • Page 12: When Removing A Water Heater From Existing Common Vent System

    At the time of removal of an existing water heater, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation.

  • Page 13: Prepare Water Heater

    Remove the two lag bolts from the wood pallet inside the water heater (FIG. 2-1). b. Detach the water heater from the lag bolts in the rear of the unit, see FIG. 2-1. Do not drop the water heater or bump the NOTICE jacket on the floor or pallet.
  • Page 14 4. Locate the propane orifice disk from the conversion kit bag. Verify that the stamping on the orifice disk matches the water heater size (see Table 2A on page 13). 5. Remove the existing orifice from the O-ring in the side of the gas valve and replace it with the orifice from the kit.

  • Page 15: Leveling The Water Heater

    5. After adjustment is complete, attach the propane conversion label (in the conversion kit bag) next to the water heater rating plate. Attach the LP caution label (in the conversion kit bag) to the left side of the unit in the lower left corner.

  • Page 16: General Venting

    General venting Direct venting options - Sidewall Vent Figure 3-1 PVC/CPVC Two-Pipe Sidewall Termination - See page 24 for more details Figure 3-3 PVC/CPVC Concentric Sidewall Termination (Models 151 - 601 Only) - See page 28 for more details Installation & Operation Manual Figure 3-2 Stainless Steel Two-Pipe Sidewall Termination - See page 25 for more details...
  • Page 17 General venting Direct venting options - Vertical Vent Figure 3-4 PVC/CPVC Two-Pipe Vertical Termination - See page 31 for more details Direct venting options - Vertical Vent, Sidewall Air Figure 3-7 PVC/CPVC Vertical Vent, Sidewall Air Stainless steel vent/air design and terminations will vary slightly by manufacturer. NOTICE (continued) Figure 3-5 Stainless Steel Two-...

  • Page 18: Install Vent And Combustion Air Piping

    The 3" Concentric Vent Kit available from Lochinvar (see Section 4 – Sidewall Termination – Optional Concentric Vent) and the 3" Concentric Vent Kit available from IPEX are both approved for use on the Armor water heater.

  • Page 19: Pvc/Cpvc Air Intake/Vent Connections

    Vent piping must be supported per the National Building Code, Section 305, Table 305.4 or as local codes dictate. Figure 3-9 Near Water Heater PVC/CPVC Venting Models 151 - 200 VENT 3”...

  • Page 20: Air Inlet Pipe Materials

    General venting Figure 3-11 Near Water Heater PVC/CPVC Venting Models 701 - 801 VENT 6” COUPLING (FIELD SUPPLIED) 6” CPVC STARTER PIECE (FACTORY SUPPLIED) THE 6” STAINLESS STEEL ADAPTER SUPPLIED WITH THE BOILER MUST BE USED FOR VENT CONNECTION TO PVC/CPVC. THE 6” CPVC STARTER PIECE MUST BE USED FOR PVC ONLY.

  • Page 21: Stainless Steel Air Intake/Vent Connections

    Only) * = This adapter must be used in addition to the water heater adapter for Saf-T vent pipe as shown in FIG. 3-12, unless approved vent other than standard diameter is used. Consult a Heat Fab representative for questions.

  • Page 22: Removing From Existing Vent

    National Fuel Gas Code, ANSI Z223.1 for U.S. installations or CSA B149.1 for Canadian installations. You must also install air piping from outside to the water heater air intake adapter. The resultant installation is direct vent (sealed combustion).

  • Page 23: Optional Room Air

    When these chemicals pass through the water heater, they can form strong acids. The acid can eat through the water heater wall, causing serious damage and presenting a possible threat of flue gas spillage or appliance water leakage into the building.

  • Page 24: Sidewall Direct Venting

    Do not exceed the maximum lengths of the outside vent piping shown in FIG. 4-1B. Excessive length exposed to the outside could cause freezing of condensate in the vent pipe, resulting in potential water heater shutdown. TO BOILER INTAKE AIR...

  • Page 25: Sidewall Direct Venting Vent/Air Termination - Sidewall

    Sidewall direct venting Vent/air termination – sidewall Figure 4-1C Alternate Stainless Steel Vent Termination - Typical Stainless Steel Sidewall Termination of Air and Vent Models 286 - 601 w/Field Supplied Fittings, Utilizing FasNSeal’s Hood Intake. Available Through FasNSeal Only TO BOILER INTAKE AIR CONNECTION FROM BOILER...

  • Page 26: Prepare Wall Penetrations

    Sidewall direct venting Figure 4-3B Alternate Clearance to Gravity Air Inlets w/ Field Supplied Fittings 12” MIN. 12” MIN. 12” MIN. Figure 4-4A Clearance to Forced Air Inlets VENT / AIR TERMINATION 7' MIN. ABOVE ANY PUBLIC WALKWAY Figure 4-4B Alternate Clearance to Forced Air Inlets w/ Field Supplied Fittings 7’...

  • Page 27: Termination And Fittings

    CSA B149.1 Installation Code. 3. The air inlet of a Armor water heater is part of a direct vent connection. It is not classified as a forced air intake with regard to spacing from adjacent water heater vents.

  • Page 28: Description And Usage

    Sidewall termination – optional concentric vent: Models 151 - 601 Description and usage Lochinvar offers optional concentric combustion air and vent pipe termination kits (Factory Kit #CVK3003 for 3” diameter - Models 151 - 200 and #CVK3007 for 4” diameter - Models 286 - 601).

  • Page 29: Sidewall Termination - Optional Concentric Vent

    Sidewall direct venting Sidewall termination – optional concentric vent: Models 151 - 601 Figure 4-10 Concentric Vent Dimensional Drawing - Models 151 - 200 Instead of cementing the smaller pipe to NOTICE the rain cap, a field-supplied stainless steel screw may be used to secure the two (2) components together when field disassembly is desired for cleaning (see FIG.
  • Page 30 Sidewall direct venting Sidewall termination – optional concentric vent: Models 151 - 601 Figure 4-13 Concentric Vent Sidewall Attachment Note: CVK3003 shown for illustration purposes. DO NOT use field-supplied couplings CAUTION to extend pipes. will occur and may cause intermittent operation.

  • Page 31: Vertical Direct Venting Vent/Air Termination - Vertical

    Vertical direct venting Vent/air termination – vertical Follow instructions WARNING determining vent location to avoid possibility of severe personal injury, death or substantial property damage. Do not connect any other appliance to WARNING the vent pipe or multiple water heaters to a common vent pipe.

  • Page 32: Prepare Roof Penetrations

    FIG. 5-2). For Canadian installations, provide clearances required by CSA B149.1 Installation Code. 3. The air inlet of an Armor water heater is part of a direct vent connection. It is not classified as a forced air intake with regard to spacing from adjacent water heater vents.

  • Page 33: Vertical Termination - Optional Concentric Vent

    Vertical termination – optional concentric vent: Models 151 - 601 Description and usage Lochinvar offers an optional concentric combustion air and vent pipe termination kit. Both combustion air and vent pipes must attach to the termination kit. The termination kit must terminate outside the structure and must be installed as shown in FIG.
  • Page 34 Vertical direct venting Vertical termination – optional concentric vent: Models 151 - 601 Do not operate the appliance with WARNING the rain cap removed or recirculation of combustion products may occur. Water may also collect inside the larger combustion air pipe and flow to the burner enclosure.

  • Page 35: Alternate Vertical Concentric Venting

    Vertical direct venting Alternate vertical concentric venting This appliance may be installed with a concentric vent arrangement where the vent pipe is routed through an existing unused venting system; or by using the existing unused venting system as a chase for vent and combustion air routing.
  • Page 36 Vertical direct venting Existing vent as a chase Follow all existing termination and clearance requirements and allowable pipe lengths. Use only approved venting materials listed in the General Venting Section of this manual. Figure 5-10 Existing Vent as a Chase AIR INLET FLUE EXHAUST SEAL...

  • Page 37: System Piping

    Basic steps are listed below along with illustrations on the following pages (FIG.’s 6-4 thru 6-8), which will guide you through the installation of the Armor water heater. 1. Connect the cold water supply to the inlet side of the water heater.

  • Page 38: Scalding

    Tank sensor: Lochinvar supplies a tank sensor. The tank sensor must be installed in the tapping provided 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 39 WATER TANK SUPPLY 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 40 (TYPICAL) STORAGE 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 41 (TYPICAL) DRAIN (TYPICAL) 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 42 STORAGE TANK DRAIN 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 43 (TYPICAL) DRAIN (TYPICAL) 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 44: Gas Connections Connecting Gas Supply Piping

    SHUTOFF VALVE (FACTORY SUPPLIED) GAS SUPPLY SEDIMENT TRAP/ DRIP LEG 3. Support piping with hangers, not by the water heater or its accessories. The gas valve and blower will not support WARNING the weight of the piping. Do not attempt to support the weight of the piping with the water heater or its accessories.

  • Page 45: Natural Gas

    Pipe sizing for natural gas 1. Refer to Table 7A for pipe length and diameter. Based on rated water heater input (divide by 1,000 to obtain cubic feet per hour). Table 7A is only for natural gas with specific gravity 0.60 inches, with a pressure drop through the gas...

  • Page 46: Check Inlet Gas Supply

    WARNING determine which fuel the water heater is set for. If set to natural gas, it may be converted to LP by installing an orifice or by making a gas valve adjustment (see pages 13 thru 15). In order to operate on LP gas, an orifice MUST BE installed or a gas valve adjustment MUST BE made.

  • Page 47: Gas Pressure

    LP) maximum during stand-by (static) mode and while in operating (dynamic) mode. If an in-line regulator is used, it must be a minimum of 10 feet from the Armor water heater. It is very important that the gas line is properly purged by the gas supplier or utility company.

  • Page 48: Field Wiring

    2. Provide and install a fused disconnect or service switch (15 amp recommended) as required by the code (see FIG. 8-1). 3. The DHW (water heater) pump is shipped loose on all Armor models. Wire the water heater pump as shown in FIG. 8-1.

  • Page 49: Low Gas Pressure Switch

    (FIG. 8-3). Rate output This output provides a 0 - 10V signal that is proportional to the firing rate of the water heater. This may be used by a BMS system to monitor the actual rate of the water heater. ModBus When the optional ModBus interface module is installed, the RS-485 ModBus cable is connected to these terminals.

  • Page 50: Runtime Contacts

    Cascade, daisy chain the wiring from the Cascade terminals on the second water heater to the Cascade terminals on the third water heater, then from the third to the forth, and so on. The connections between heaters can be made in any order, regardless of the addresses of the water heaters.
  • Page 51 Installation & Operation Manual Field wiring (continued) Figure 8-3 Low Voltage Field Wiring Connections...

  • Page 52: Condensate Disposal Condensate Drain

    1. This water heater is a high efficiency appliance that produces condensate. 2. The side of the water heater has a 1/2 inch PVC union for connection of a 1/2 inch PVC pipe (FIG. 9-1). 3. Slope condensate tubing down and away from the water heater into a drain or condensate neutralizing filter.

  • Page 53: Startup

    Start-up Chlorine concentration less than 200 ppm 1. Do not fill the water heater or operate with water containing chlorine in excess of 200 ppm. 2. Filling with chlorinated fresh water should be acceptable since drinking water chlorine levels are much lower.

  • Page 54: Final Checks Before Starting The Water Heater

    Check flame and combustion 1. Turn the main power off to the water heater by placing the “On/Off” switch in the OFF position. 2. Remove the flue temperature sensor from the flue pipe connection.

  • Page 55: For Your Safety Read Before Operating

    Start-up (continued) Figure 10-2 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 56 Installation & Operation Manual Start-up Figure 10-3 Operating Instructions - Models 400 - 801...
  • Page 57 SMART SYSTEM control will turn on the water heater pump. Propane When the DHW call for heat ends, the water heater pump will continue to run for a period of time. This pump delay is set at the factory to 60 seconds. If a shorter or longer delay is desired, the appropriate parameter in the control must be changed.
  • Page 58 The SMART SYSTEM control has a built-in clock that it uses for its night setback feature and for logging events. This clock must be set when the water heater is installed, and anytime the water heater has been powered off for more than 4 hours.

  • Page 59: Operating Information General

    The control module regulates blower speed to control the 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 60: Water Heater Temperature Regulation

    Runtime and alarm outputs The water heater provides dry contacts for indicating when the water heater is running, and when it is unable to operate. Runtime and cycle counting The control uses a timer to monitor the total hours of burner operation.

  • Page 61: Cascade

    Lead/Lag or Efficiency Optimization control methods. Once the Leader water heater receives a call for heat from a tank sensor, BMS or Modbus, the control will determine what the set point will be. A fixed temperature set point can be programmed into the control.

  • Page 62: Sequence Of Operation

    Sequence of operation OPERATION 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. The control turns on power to the louver relay. The louver proving switch, air pressure switch, and blocked drain switch must close.

  • Page 63: Armor Water Heater Control Module

    Installation & Operation Manual Operating information (continued) Armor water heater control module Use the control panel (FIG. 11-1) to set temperatures, operating conditions, and monitor water heater operation. Figure 11-1 Control Panel NAVIGATION DIAL (PRESS OR TURN) RESET KEY LEFT SELECT KEY...

  • Page 64: Status Display Screens

    Operating information Figure 11-2 Status Display Screen Section Display STANDBY PREPURGE IGNITION (Water heater Status Bar) POSTPURGE SHUTDOWN BLOCKED (Call for Heat Indicators) Status Display Screens The unit has not received a call for heat from a remote thermostat nor has it received a call for heat from a DHW thermostat.
  • Page 65 The speed signal sent to a variable speed water heater pump in percent. A 0 - 10V signal indicating the firing rate of the water heater. The total hours of operation in the DHW Mode. The total burner cycles in the DHW Mode.

  • Page 66: Status Display Screens

    Turning the NAVIGATION dial will increase or decrease the current setting. SHDN Press the RIGHT SELECT key to turn the water heater OFF. Press the RIGHT SELECT key to turn the water heater ON. Press the RIGHT SELECT key to cancel the shutdown operation.

  • Page 67: Owner Maintenance

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

  • Page 68: 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 69: Check Water Heater Relief Valve

    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 70: Check Burner Flame

    1. Shut down water heater: • Follow the “To Turn Off Gas to Appliance” instructions for the water heater in Section 10 - Startup. • 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 71: Oiled Bearing Circulators

    38 for more information regarding Delta T. Description Oiled bearing circulators 1. The circulator shipped with the Armor water heater is water-lubricated. No oiling is required. 3mm Allen Wrench 2. Check other circulators in the system. Oil any circulators requiring oil, following circulator manufacturer’s...

  • Page 72: Diagrams

    Diagrams Figure 13-1 Ladder Diagram 120VAC TERMINAL STRIP 120V SUPPLY "L" ON / OFF SWITCH X1-6 X5-9 X4-3 AW 801 ONLY CN5-5 CN7-1 CN7-3 PC INTERFACE ALARM CONTACTS RUN-TIME CONTACTS TANK SENSOR SHIELD CASCADE SHIELD 0-10V RATE 0-10V SHIELD MODBUS SHIELD JUNCTION BOX INTEGRATED CONTROL...

  • Page 73: Wiring Diagram

    Diagrams (continued) Figure 13-2 Wiring Diagram ALARM CONTACTS RUN-TIME CONTACTS 24 VAC LOUVER RELAY COIL LOUVER PROVING SWITCH GAS PRESSURE SWITCH FLOW SWITCH TANK THERMOSTAT TANK SENSOR SHIELD CASCADE SHIELD 0-10V RATE 0-10V SHIELD MODBUS OPTION SHIELD CN7-1 24 VAC CN7-2 WATER CN7-3...
  • Page 74 Installation & Operation Manual Notes...
  • Page 75 Installation & Operation Manual Notes...

  • Page 76: Revision Notes

    Revision Notes: Revision A (ECO #C06238) initial release. Revision B (ECO #C07442) new layout in InDesign, piping diagram on page 43 (ECR #R03671), and edits made to the Ratings Page (page 7). Revision C (ECO #C07575) changes made (mixing valves) to the piping diagrams on pages 39 - 43, changes made to the gas supply piping images on page 44 (ECR R03740), the addition of the rope gasket notice on page 71 (ECR R03940), change water pipe clearances from...

This manual is also suitable for:

Armor awn151pmArmor awn200pmArmor awn286pmArmor awn400pmArmor awn501pmArmor awn601pm ... Show all

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