Lochinvar 150 - 500 manual

Service Manual Models: 150 - 500 St arting Serial #H07H10046464 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 I nstallation and Operation Manual, before installing. P erfor m steps in the or der given. Failure t o com[...]

2 Hazar d definitions The following defined terms are used thr oughout this manual to bring attention to the presenc e 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 which, if not avoided, w ill[...]

Service Manual Please r ead bef ore pr oceeding 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 heater serviced/inspected by a qualified serv ice t echnician at least annually . Failure t o comply with [...]

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[...]

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

1 Ser vice 6 Service Manual GAS PRESSURE SWITCH DHW TH ERMOS T A T FLOW SW ITCH T ANK SENSOR SEQUENCE R / BUILDING MANAG EMEN T SYSTE M 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 CUTOFF BLOCKED DRAI N SW ITCH DISPLA Y P ANEL PC INTERF ACE SMA R T SYS[...]

Service Manual 7 LOW VOL T AGE CONNEC TION BOARD SMA R T SYSTEM CONTROL BOARD ALARM BELL AUX . DEVICE RELA Y RUNTIME CONT ACT S 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)[...]

1 Ser vice 8 Service Manual General Oper ation How the w a ter heater operates The A rmor water heater uses an advanc ed stainless steel heat ex changer and an electronic c ontrol module that allo ws fully condensing operation. The blo wer pulls in gas and air and pushes flue products out of the water heater through the heat ex changer and flue pip[...]

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[...]

1 Ser vice 10 Service Manual Display panel menu access T able 1B Use this procedure to access menus from the display p anel 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 [...]

Service Manual 11 Display panel parameter access T able 1C This is a typical example of accessing a p arameter , shown for parameter 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[...]

1 Ser vice 12 Service Manual Parameter table T able 1D This t able 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 Softw[...]

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 w ill be display ed when parameter A1 has been accessed. This parameter is not changeable. User code The U[...]

1 Ser vice 14 Service Manual H: Control modes Control source The contr ol source paramet er selects the method used to contr ol 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 modulat es the water heater based on the us[...]

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 t o 0 will disable the pump. This parameter is adjustable by the installer by accessing parameter I3 . The time range for this parameter is 0 minutes[...]

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,[...]

2 Maintenance Service Manual 17 2 Maintenance (continued) Follo w the serv ice and maintenanc e proc edures giv en throughout this manual and in c omponent literature shipped with the water heater . Failure t o perform the ser vice and maintenanc e could result in damage t o the water heater or syst em. Failur e to follow the dir ections in this ma[...]

2 Maintenance 18 Service Manual Flue vent system and air piping 1. Visually inspect the entir e flue gas venting syst em and air piping for blockage, deterioration or leakage. R epair any 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 disc harge and air intake ar[...]

2 Maintenance Service Manual 19 2 Maintenance (continued) Inspect ignition and flame sense electrodes 1. R emov e the ignition and flame sense electrodes from the water heater heat e xc hanger access c ov er . 2. Re mov e any deposits ac cumulated on the ignition/flame sense electrode using sandpaper . If the electrodes cannot be cleaned satisfacto[...]

20 Service Manual 2 Maintenance Check flame signal 1. A t high fire the flame signal shown on the display should be at least 10 microamps. 2. A lowe r flame signal may indicate a fouled or damaged flame sense electrode. If cleaning the flame sense electrode does not improv e, ground wiring is in good condition, and ground contin uity is satisfactor[...]

3 T r oubleshooting Service Manual 21 Label all wires prior to disconnection when serv icing controls. W ir ing errors can cause improper and danger ous operation. Always disconnect po wer t o the water heater befor e serv icing. Failure t o comply c ould result in seve re personal injur y , death, or substantial property damage. Nev er jumper (byp[...]

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. T urn switch to the ON position. • Check 120 V AC through the ON/OFF switch. • Check wiring harness c[...]

3 T r oubleshooting Service Manual 23 3 T r oubleshooting (continued) T able 3B - Inlet/Outlet System Sensor Resist ance 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 Re[...]

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[...]

Service Manual 25 3 T r oubleshooting (continued) T able 3E T roubleshooting Chart - Fault Messages Displayed on Water 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[...]

26 Service Manual 3 T r oubleshooting T able 3E (continued from previous p age) 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 ha[...]

Service Manual 27 3 T r oubleshooting (continued) T able 3E (continued from previous p age) 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 re[...]

3 T r oubleshooting 28 Service Manual T able 3E (continued from previous p age) 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.) [...]

Service Manual 29 3 T r oubleshooting (continued) T able 3E (continued from previous p age) 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 di[...]

3 T r oubleshooting 30 Service Manual T able 3E (continued from previous p age) 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[...]

Service Manual 31 3 T r oubleshooting (continued) T able 3E (continued from previous p age) 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 [...]

3 T r oubleshooting 32 Service Manual Combustion Analysis Pr ocedur e 1. T ur n the main pow er off to the wat er heater by placing the “On/Off ” switch in the OFF position. 2. Re mov e the flue temperature sensor fr om the flue pipe connection. No t e: Combustion measurements will be made at this point. 3. T ur n the main pow er on to the wate[...]

Service Manual 33 3 T r oubleshooting (continued) Gas valv e adjustment procedur e If adjust ment of the gas valve is deemed necessary , use the following procedur es: ( Not e : The proc edures belo w 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[...]

34 NOTES[...]

35 NOTES[...]

Revision Notes: Revision B (AW -SER-Rev B) reflects 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[...]