Lochinvar 151 - 801 manual

Service Manual Models: 151 - 801 T h i s m a n u a l m u s t o n l y b e u s e d b y a qualified heating installer / serv ice technician. Read all instructions, including this manual and the Armor W ater H eater Installation and Operation Manual, before installing. P erform steps in the order given. Failure t o comply could result in sev ere person[...]

2 Hazar d definitions The following defined terms are used thr oug hout this manual to bring attention t o the presence of hazards of various r isk level s or to important information concerning the life of the product.  DANGER  W ARNING  CAUTION CAUTION NOTICE D ANGER indicates an imminently hazardous situation whic h, if not avoided, wil[...]

Service Manual Please r ead bef or e proceeding Installer – R ead all instructions, including this manual and the Armor W ater H eater Installation and Operation Manual, before installing. P erform steps in the order give n. Ha ve this water heat er ser viced/inspected by a qualified serv ice t echnician at least annually . Failure t o comply wit[...]

4 Service Manual W hat is in this manual? Ser vice T he Ar mor water hea ter display • Display panel r eadout, buttons and their functions Control module inputs • Control module inputs and options Control module outputs • Control module outputs and options General • Ho w the water heater operates • Ho w the control module operates • A c[...]

1 Ser vice Service Manual 5 NA VIGA TION DIAL (PRESS OR TURN) RIGHT SELECT KEY (SOFT KEY) LEFT SELECT KEY (SOFT KEY) RESET KEY T he Ar mor wa ter heater display The information on the bottom of the display sho ws the functions of the two SELECT keys (on either c orner), and the N A VIGA TION dial (in the cent er): MENU = Left SELECT K ey SETPOINTS [...]

1 Ser vice 6 Service Manual GAS PRESSURE SW ITCH DHW T HERMOS T A T FLOW S W ITCH T ANK SENSO R SEQUENCER / BUILDI NG MANAGEMENT SYSTEM LOW VOL T A GE CONNECT ION BOARD INLET TEM PERA TURE SENSOR OUTLET TEMPERA T URE SENSOR FLUE GAS SENSOR LOUVER PROVING SW ITCH FLAME SENSOR LOW WA TER C UTOFF BLOCKED DRAI N SW ITCH DISPLA Y P ANEL PC INTERF ACE SM[...]

Service Manual 7 LOW VOL T AGE CONNECT ION BOARD SMA R T SYST EM CONTROL BOARD ALARM BELL LOUVER RELA Y RUN TI ME CONT ACTS SEQUENCER / BUILDI NG MANA GEMEN T SYSTE M W A TER HEA TER P UMP IGNITOR BLOW ER GAS V AL VE D I S P L AY PA N E L PC INTERF ACE BUIL DING RECIRCULA TION PUMP Control outputs 1 Ser vice (continued)[...]

1 Ser vice 8 Service Manual General Oper ation How the w ater heater operates The A r mor water heat er uses an advanced stainless steel heat ex changer and an electronic control module that allo ws fully condensing operation. The blower pulls in gas and air and pushes flue products out of the water heater through the heat ex changer and flue pipin[...]

Service Manual 9 T able 1A Sequence of operation 1 Ser vice (continued) OPERATION DISPLAY 1. The control will turn on the water heater pump (always ON except in Night Setback). The flow switch and/or L WCO must close. 2. The control turns on power to the louver relay . The louver proving switch, air pressure switch, and blocked drain switch must cl[...]

1 Ser vice 10 Service Manual Display panel menu access T able 1B Use this procedure to access menus from the display panel B UTTON SCREEN ST A TUS OPERA TION DISPLA Y [SHDN] Press the RIGHT SELECT soft key [SHDN]. [YES] Press the LEFT SELECT soft key [YES]. [MENU] Press and hold the LEFT SELECT soft key [MENU] for five (5) seconds. Rotate the NA VI[...]

Service Manual 11 Display panel parameter access T able 1C This is a typical example of accessing a parameter , shown for p arameter DHW Settings, T ANK MIN Setpt 1 Ser vice (continued) B UTTON SCREEN ST A TUS OPERA TION DISPLA Y This example shows how to access parameter T emperature Settings. The first display shown is at the beginning of the men[...]

1 Ser vice 12 Service Manual Parameter table T able 1D This table lists SMAR T SYSTEM control module parameters and where to access them Menu Sub Item Description See Pa ge User Access Installer Access Display Modify Display Modify A 1 Date and T ime 14 Ye s Ye s Ye s Ye s 2 Software V ersion (read only) 14 No No Ye s No 3 T emperature Units (ºC/?[...]

1 Ser vice (continued) Service Manual Menu Sub Item Description See Pa ge User Access Installer Access Display Modify Display Modify F 1 BMS T stat Input (Active/Inactive) 16 No No Ye s Ye s 2 BMS (Active/Inactive) 16 No No Ye s Ye s 3 ModBus (Active/Inactive) 16 No No Ye s Ye s 4 ModBus T/O (Timeout) 16 No No Ye s Ye s 5 Cascade Address 16 No No Y[...]

1 Ser vice 14 Service Manual Viewable and changeable contr ol parameter s CAUTION Before changing parameters, note the settings so that the unit can be returned to its original oper ating parameters. A: General Date and Time The control uses an int ernal clock for the nig ht setback feature and for logging of events. For these featur es to work cor[...]

1 Ser vice (continued) 15 Service Manual T ank Minimum Set Point This setting controls the minim um user set point for the tank temperature. The installer can adjust this by acc essing parameter D4 . The minimum setting is 60°F (16°C) and the maximum setting is the maximum tank set point (parameter D5 ). T ank Maximum Set Point This setting contr[...]

Service Manual 16 1 Ser vice F: Control modes BMS Thermost at Input (Active / Inactive) W hen controlling the water heat er through the 0 - 10V BMS input or through M odBus, the water heat er can be enabled one of two wa ys. W ith par ameter F1 set t o A CTIVE, the water heater will be enabled by closing the T ank Thermostat input. W ith parameter [...]

1 Ser vice (continued) Service Manual 17 Maximum Cascade Outlet Set Point This parameter determines the set point used by the individual water heaters in a Cascade. W hen a water heater is commanded t o fire by the Leader water heat er , it w ill attempt to ac hie v e this temperature at its outlet. The Leader water heat er w ill limit the modulati[...]

1 Ser vice Service Manual 18 Service Notification Cycles W hen the water heater contr ol determines that a scheduled serv ice is due based on the number of water heater cycles, the water heater displa y will alternate the standard water heater display t ext w ith the message SER VICE DUE every 5 seconds. This parameter is adjustable by the installe[...]

2 Maintenance Service Manual 19 Maintenance and annual star tup T able 2A Service and Maintenance Schedules Ser vice tec hnician (see the following p ages for instructions) General: • Address reported problems • Inspect interior; clean and vacuum if necessary; • Clean condensate trap and fill with fresh water • Check for leaks (water , gas,[...]

2 Maintenance 20 Service Manual Follo w the ser vice and maintenance pr ocedures given thr oughout this manual and in component literature shipped with the water heater . Failure t o perform the ser v ice and maint enance could result in damage t o the water heater or syst em. Failur e to follow the directions in this manual and c omponent literatu[...]

2 Maintenance (continued) 21 Service Manual Flue vent system and air piping 1. V isually inspect the entire flue gas venting system and air piping for blockage, deterior ation or leakage. Repair an y joints that show signs of leakage. V erify that air inlet pipe is connected and pr operly sealed. 2. V erify that water heater vent disc harge and air[...]

2 Maintenance Service Manual 22 2 Maintenance Inspect ignition and flame sense electrodes 1. R emove the ignition and flame sense electrodes from the water heater heat e xchanger acc ess cov er . 2. Re move an y deposits accumulated on the ignition/flame sense electrode using sandpaper . If the electrodes cannot be cleaned satisfactorily , r eplace[...]

Service Manual 2 Maintenance (continued) Check flame signal 1. At high fire the flame signal sho w n on the display should be at least 10 microamps. 2. A lowe r flame sig nal may indicat e a fouled or damaged flame sense electrode. If cleaning the flame sense electrode does not impro ve, ground wir ing is in good condition, and ground contin uit y [...]

3 T r oubleshooting Service Manual 24 Label all wires prior to disconnection when serv icing controls. Wiring errors can cause improper and dangerous operation. Alwa ys disconnect po wer to the water heater before serv icing. F ailure to comply could result in sev ere personal injur y , death, or substantial propert y damage. Nev er jumper (bypass)[...]

25 Service Manual 3 T r oubleshooting (continued) T able 3A T roubleshooting Chart - No Display FAULT CAUSE CORRECTIVE ACTION No Display - No 120 V AC supplied to unit. • Check external line switch, fuse, or breaker . • Check position of ON/OFF switch. Turn switch to the ON position. • Check 120 V AC through the ON/OFF switch. • Check wir[...]

Service Manual 26 3 T r oubleshooting T able 3B - Inlet System Sensor Resistance vs. T emperature T emperature °F Resist ance Ω T emperature °F Resist ance Ω 50 18,780 158 1,990 68 12,263 176 1,458 86 8,194 194 1,084 104 5,592 212 817 122 3,893 -- -- 140 2,760 -- -- Checking temperature sensor s The water heater t emperature sensors (inlet wate[...]

3 T r oubleshooting (continued) 27 Service Manual T able 3E T roubleshooting Chart - Noisy System FAULT CAUSE CORRECTIVE ACTION Noisy Operation - Supply gas problem. Natural gas pressures should be between 4 inches w .c. and 14 inches w .c. LP gas pressures should be between 8 inches w .c. and 14 inches w .c. • Refer to Section 7 - Gas Connection[...]

Service Manual 28 3 T r oubleshooting T able 3F T roubleshooting Chart - Fault Messages Displayed on W ater Heater Interface FAULT DESCRIPTION CORRECTIVE ACTION Gas Pressur e SW (will require a manual reset once the c ondition has been correct ed. Press the RESET butt on on the SMAR T SYSTEM display to reset.) Either the manual reset low gas pressu[...]

29 Service Manual 3 T r oubleshooting (continued) T able 3F (continued from previous page) T roubleshooting Chart - Fault Messages Displayed on Water Heater Interface FAULT DESCRIPTION CORRECTIVE ACTION Anti-cy cling The main control board has received a call for heat too quickly after the previous call for heat has ended. • The control board wil[...]

Service Manual 30 3 T r oubleshooting T able 3F (continued from previous page) T roubleshooting Chart - Fault Messages Displayed on Water Heater Interface FAULT DESCRIPTION CORRECTIVE ACTION No Flam e Running (will require a manual reset once the c ondition has been correct ed. Press the RESET butt on on the SMAR T SYSTEM display to reset.) The uni[...]

3 T r oubleshooting (continued) 31 Service Manual T able 3F (continued from previous page) T roubleshooting Chart - Fault Messages Displayed on Water Heater Interface FAULT DESCRIPTION CORRECTIVE ACTION Flame Sequence (will require a manual reset once the c ondition has been correct ed. Pr ess the RESET button on the SMAR T SYSTEM display to reset.[...]

3 T r oubleshooting Service Manual 32 T able 3F (continued from previous page) T roubleshooting Chart - Fault Messages Displayed on Water Heater Interface FAULT DESCRIPTION CORRECTIVE ACTION F an Low OR F an Speed Low (will require a manual reset once the c ondition has been correct ed. Pr ess the RESET button on the SMAR T SYSTEM display to reset.[...]

Service Manual 33 3 T r oubleshooting (continued) T able 3F (continued from previous page) T roubleshooting Chart - Fault Messages Displayed on Water Heater Interface FAULT DESCRIPTION CORRECTIVE ACTION Sensor Shor ted (will require a manual reset once the c ondition has been correct ed. Pr ess the RESET button on the SMAR T SYSTEM display to reset[...]

3 T r oubleshooting 34 Service Manual T able 3F (continued from previous page) T roubleshooting Chart - Fault Messages Displayed on Water Heater Interface FAULT DESCRIPTION CORRECTIVE ACTION Outlet T emp High Outlet water temperature has exceeded the maximum outlet water temperature. • V erify that the system is full of water and that all air has[...]

Service Manual 35 3 T r oubleshooting (continued) T able 3F (continued from previous page) T roubleshooting Chart - Fault Messages Displayed on Water Heater Interface FAULT DESCRIPTION CORRECTIVE ACTION Low 24 V AC 120 V AC input to the main control board has dropped below 80 V AC. • Check 120 V AC supply to the transformer . • Check wiring con[...]

3 T r oubleshooting 36 Service Manual Combustion Analysis Pr ocedur e 1. T ur n the main pow er off to the water heater b y placing the “On/Off ” switch in the OFF position. 2. Re move the flue temperature sensor fr om the flue pipe connection. No te : Combustion measurements will be made at this point. 3. T ur n the main pow er on to the water[...]

Service Manual 37 3 T r oubleshooting (continued) Gas valv e adjustment pr ocedure If adjust ment of the gas valve is deemed necessary , use the following procedur es: ( No te : The procedur es in this section are model specific.) Models 151 - 286 Locate the throttle adjustment scr ew on the side of the venturi valv e (FIG. 3-2). U sing a screwdriv[...]

38 Model 501 Locate the throttle adjustment scr ew on top of the gas valv e, see FIG. 3-4. U sing a screw dr iv er , tur n the screw a 1/4 turn counter clockw ise to increase CO 2 lev els or a 1/4 turn clockw ise to decrease CO 2 lev els. After one adjustment on the valve, follow the Combustion Analysis Proc edure on page 36 of this manual to measu[...]

Notes 39[...]

Revision Notes: Revision A (ECO #C06238) initial release. AWII-SER Rev A 8/10[...]