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Lochinvar 150 - 800 manual

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Table of contents for the manual

  • Page 1

    Service Manual Models: 150 - 800 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[...]

  • Page 2

    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[...]

  • Page 3

    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[...]

  • Page 4

    4 Service Manual W hat is in this manual? Ser vice Near wa ter heater piping • T y pical system c omponents 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 h[...]

  • Page 5

    1 Ser vice Service Manual 5 T he Ar mor wa ter heater display[...]

  • Page 6

    1 Ser vice 6 Service Manual GAS PRESSURE SWITCH (OPTIONAL) DHW THERMO ST A T FLOW SW ITCH TA N K S E N S O R SEQU ENCER / BU ILDING MANAGEM ENT SYSTEM LOW VOL T AGE CONNEC TION BOARD INLET TEMPERA TURE SENSOR OUTLET TEMPERA TURE SENSOR FLUE GAS SENSOR HIGH LIMIT SENSOR FLAME SENSOR LOW WA TER CUT OFF (OPTIONAL) BLOCKED DRAI N SW ITCH D I S P L AY P[...]

  • Page 7

    Service Manual 7 LOW VOL T AGE CONNEC TION BOARD SMA R T SYSTEM CONTROL BOARD ALARM BELL AUX . DEVICE RELA Y RUNTIME CONT ACTS SEQU ENCER / B UILDING MANAGEMENT SYSTEM DHW PUMP IGNITER BLOW ER GAS V AL VE D I S P L AY PA N E L PC INTERF ACE Control outputs 1 Ser vice (continued)[...]

  • Page 8

    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[...]

  • Page 9

    Service Manual 9 Sequence of oper ation T able 1A Sequence of operation OPERATION DISPLAY 1. Upon a call for heat, the control turns on the water heater pump. WHR: Standby OUT: 123.8F(129) 2. The control connects 120 V AC to the blower . The blower does not run at this time. • If the unit is equipped with a flow switch, it must close before the c[...]

  • Page 10

    1 Ser vice 10 Service Manual Display panel menu access T able 1B Use this procedure to access menus from the display panel DISPLAY BUTTON OPERATION Enter Menu Code: 000 0 Hold for 5 seconds -- display will change Press 9 times to change last digit in readout to "9" Press 2 times to move to the second digit Press 3 times to change second d[...]

  • Page 11

    Service Manual 11 Display panel parameter access T able 1C This is a typical example of accessing a parameter , shown for p arameter H3, cascade address DISPLAY BUTTON OPERATION >A General B N/A Beginning of menu listings. - >C Data Log D Functions Press 1 time to toggle menu listing D O W N >E WHR Settings F N/A Press 2 times to toggle me[...]

  • Page 12

    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 PAGE USER ACCESS INSTALLER ACCESS DISPLAY MODIFY DISPLAY MODIFY A 1 Boiler Model 13 Ye s No Ye s No 2 User Code 13 Ye s Ye s Ye s Ye s 3 Date and T ime 13 Ye s Ye s Ye s Ye s 4 Softwa[...]

  • Page 13

    1 Ser vice Service Manual 13 1 Ser vice (continued) Viewable and changeable contr ol parameter s A: General Boiler model The control will display “ Armor Heater” as the model number because the same contr ol is used on several models. This will be display ed when par ameter A1 has been ac cessed. This parameter is not changeable. User code The [...]

  • Page 14

    1 Ser vice 14 Service Manual H: Control modes Control source The contr ol source parameter selects the method used to c ontrol the modulation of the water heat er . This parameter is adjustable by the installer by ac cessing parameter H2 . The control methods are as follo ws: 1 - Thermostat. The c ontrol modulates the water heat er based on the use[...]

  • Page 15

    Service Manual 15 I: Circulation pumps DHW pump delay The DHW pump delay parameter sets the length of time the DHW (WHR) pump w ill run after a heater demand has been satisfied. Setting the delay time to 0 will disable the pump. This parameter is adjustable by the installer b y accessing parameter I3 . The time range for this parameter is 0 minutes[...]

  • Page 16

    2 Maintenance 16 Service Manual 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,[...]

  • Page 17

    2 Maintenance Service Manual 17 2 Maintenance (continued) 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 perfor m the serv ice and maint enance could result in damage t o the water heater or syst em. Failur e to follow the directions in this manu[...]

  • Page 18

    2 Maintenance 18 Service Manual Flue vent system and air piping 1. Visually inspect the entir e 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 er ify that water heat er vent discharge and air intak e ar[...]

  • Page 19

    2 Maintenance Service Manual 19 2 Maintenance (continued) 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 satisfactoril[...]

  • Page 20

    20 Service Manual 2 Maintenance 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 is satisf[...]

  • Page 21

    3 T r oubleshooting Service Manual 21 Label all wires prior to disconnection when serv icing controls. Wiring errors can cause improper and danger ous operation. Always disc onnect power t o the water heater befor e ser vicing. Failure t o comply could result in sev ere personal injur y , death, or substantial property damage. Nev er jumper (bypass[...]

  • Page 22

    22 Service Manual 3 T r oubleshooting 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 wiring harness co[...]

  • Page 23

    3 T r oubleshooting Service Manual 23 3 T r oubleshooting (continued) T able 3B - Inlet/Outlet 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 -- -- T able 3C - Flue T emperature Sensor Res[...]

  • Page 24

    3 T r oubleshooting 24 Service Manual T able 3D 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 Connections of the Arm[...]

  • Page 25

    Service Manual 25 3 T r oubleshooting (continued) T able 3E 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 lo[...]

  • Page 26

    26 Service Manual 3 T r oubleshooting T able 3E (continued from previous page) T roubleshooting Chart - Fault Messages Displayed on Water Heater Interface FAULT DESCRIPTION CORRECTIVE ACTION No Flame Ign (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 unit has[...]

  • Page 27

    Service Manual 27 3 T r oubleshooting (continued) T able 3E (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 res[...]

  • Page 28

    3 T r oubleshooting 28 Service Manual T able 3E (continued from previous page) T roubleshooting Chart - Fault Messages Displayed on Water Heater Interface FAULT DESCRIPTION CORRECTIVE ACTION Manual Reset High Limit (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.) T[...]

  • Page 29

    Service Manual 29 3 T r oubleshooting (continued) T able 3E (continued from previous page) T roubleshooting Chart - Fault Messages Displayed on Water Heater Interface FAULT DESCRIPTION CORRECTIVE ACTION F an High OR F an Speed High (will require a manual reset once the c ondition has been correct ed. Pr ess the RESET button on the SMAR T SYSTEM dis[...]

  • Page 30

    3 T r oubleshooting 30 Service Manual T able 3E (continued from previous page) T roubleshooting Chart - Fault Messages Displayed on Water Heater Interface FAULT DESCRIPTION CORRECTIVE ACTION T emp O/Shoot (continued) The temperature rise across the heat exchanger has exceeded the set parameters for the water heater . • V erify that the system is [...]

  • Page 31

    Service Manual 31 3 T r oubleshooting (continued) T able 3E (continued from previous page) T roubleshooting Chart - Fault Messages Displayed on Water Heater Interface FAULT DESCRIPTION CORRECTIVE ACTION Ser vice Blk While the unit is in Service Mode, the outlet temperature has exceeded 185°F . • Establish a heating load to remove the heat from t[...]

  • Page 32

    3 T r oubleshooting 32 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[...]

  • Page 33

    Service Manual 33 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 below are model specific.) Models 150 - 285 Locate the throttle adjustment scr ew on the side of the venturi valv e (FIG. 3-2). U sing a screwdriver , turn [...]

  • Page 34

    34 Model 500 Locate the throttle adjustment scr ew on top of the gas valv e, see FIG. 3-4. U sing a screw dr iv er , turn the scr ew 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 32 of this manual to measu[...]

  • Page 35

    35 NOTES[...]

  • Page 36

    Revision Notes: Revision B (AW-SER-Rev B) reflect s 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 per[...]