Lochinvar 150 - 500 User manual

Installation & Operation
Manual
Models: 150 - 500
Starting Serial #H07H10046464
This manual must only be used 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. Failure to
comply could result in severe
personal injury, death, or substantial
property damage.
WARNING
Save this manual for future reference.
AW-I-O Rev I

2
Hazard definitions
The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or
to important information concerning the life of the product.
DANGER
WARNING
CAUTION
CAUTION
NOTICE
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious
injury.
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious
injury.
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate
injury.
CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not
avoided, may result in property damage.
NOTICE indicates special instructions on installation, operation, or maintenance that are important but not
related to personal injury or property damage.
HAZARD DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2
PLEASE READ BEFORE PROCEEDING . . . . . . . . . . . . 3
THE ARMOR WATER HEATER -- HOW IT WORKS . . . . 4
RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1. DETERMINE WATER HEATER LOCATION
Provide Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Provide Air Openings to Room . . . . . . . . . . . . . . . . . . . . 10
Flooring and Foundation . . . . . . . . . . . . . . . . . . . . . . . . 10
Residential Garage Installation . . . . . . . . . . . . . . . . . . . . 10
Vent and Air Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Prevent Combustion Air Contamination . . . . . . . . . . . . . . 10
Corrosive Contaminants and Sources . . . . . . . . . . . . . . . 11
Removing a Water Heater from Existing Common Vent . 11
2. PREPARE WATER HEATER
Remove Water Heater from Wood Pallet . . . . . . . . . . . . 12
Gas Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Leveling the Water Heater . . . . . . . . . . . . . . . . . . . . . 13
3. GENERAL VENTING
Direct Venting Options . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Install Vent and Combustion Air Piping . . . . . . . . . . . . . . 15
Vent Piping Materials . . . . . . . . . . . . . . . . . . . . . . . . . 15
Requirements for Installation in Canada . . . . . . . . . . . . . 15
Air Intake/Vent Connections . . . . . . . . . . . . . . . . . . . . . . 16
Air Inlet Pipe Materials . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Min./Max. Combustion Air & Vent Piping Lengths . . . . . . 17
Removing from Existing Vent . . . . . . . . . . . . . . . . . . . . . 17
Vent and Air Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4. SIDEWALL DIRECT VENTING
Vent/Air Termination - Sidewall . . . . . . . . . . . . . . . . . . . . 18-21
Determine Location . . . . . . . . . . . . . . . . . . . . . . . . . . 18-19
Prepare Wall Penetrations . . . . . . . . . . . . . . . . . . . . . 20
Termination and Fittings . . . . . . . . . . . . . . . . . . . . . . . 20
Multiple Vent/Air Terminations . . . . . . . . . . . . . . . . . . 20
Sidewall Termination - Optional Concentric Vent . . . . . . 21-23
5. VERTICAL DIRECT VENTING
Vent/Air Termination - Vertical . . . . . . . . . . . . . . . . . . . . . 24-25
Determine Location . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Prepare Roof Penetrations . . . . . . . . . . . . . . . . . . . . . 25
Termination and Fittings . . . . . . . . . . . . . . . . . . . . . . . 25
Multiple Vent/Air Terminations . . . . . . . . . . . . . . . . . . 25
Vertical Termination - Optional Concentric Vent . . . . . . . 26-27
6. HYDRONIC PIPING
System Water Piping Methods . . . . . . . . . . . . . . . . . . . . 28
Flow Switch and Relief Valve Installation . . . . . . . . . . . . 28
Flow Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Water Chemistry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Piping Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7. GAS CONNECTIONS
Connecting Gas Supply Piping . . . . . . . . . . . . . . . . . . . . 35
Natural Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Pipe Sizing for Natural Gas . . . . . . . . . . . . . . . . . . . . 36
Natural Gas Supply Pressure Requirements . . . . . . . 36
Propane Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Pipe Sizing for Propane Gas . . . . . . . . . . . . . . . . . . . 36
Propane Supply Pressure Requirements . . . . . . . . . . 36
Check Inlet Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
High and Low Gas Pressure Switches . . . . . . . . . . . . . . 38
Gas Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 38
8. FIELD WIRING
Line Voltage Connections . . . . . . . . . . . . . . . . . . . . . . . . 39
Low Voltage Connections . . . . . . . . . . . . . . . . . . . . . . . . 40
Wiring of the Cascade . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
9. CONDENSATE DISPOSAL
Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
10. STARTUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44-49
11. OPERATING INFORMATION
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Cascade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51-52
Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Armor Water Heater Control Module . . . . . . . . . . . . . . . . 54
Status Display Screens . . . . . . . . . . . . . . . . . . . . . . . . . . 55-57
12. MAINTENANCE
Maintenance & Annual Startup . . . . . . . . . . . . . . . . . . . . 58-61
13. DIAGRAMS
Ladder Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Revision Notes . . . . . . . . . . . . . . . . . . . . . . . . . Back Cover
Contents

Installation & Operation Manual
Please read before proceeding
Installer – Read all instructions, including
this manual and the Armor Water Heater
Service Manual, before installing. Perform
steps in the order given.
Have this water heater serviced/inspected
by a qualified service technician, at least
annually.
Failure to comply with the above could
result in severe personal injury, death or
substantial property damage.
Failure to adhere to the guidelines on this
page can result in severe personal injury,
death, or substantial property damage.
When servicing the water heater –
• To avoid electric shock, disconnect electrical supply
before performing maintenance.
• To avoid severe burns, allow the water heater to cool
before performing maintenance.
Water heater operation –
• Do not block flow of combustion or ventilation air to
the water heater.
• Should overheating occur or gas supply fail to shut off,
do not turn off or disconnect electrical supply to
circulator. 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
appliance that has been under water must be replaced.
When calling or writing about the water
heater – Please have the water heater model
and serial number from the water heater
rating plate.
Consider piping and installation when
determining water heater location.
Any claims for damage or shortage in
shipment must be filed immediately
against the transportation company by the
consignee.
Factory warranty (shipped with unit) does
not apply to units improperly installed or
improperly operated.
3
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.
WARNING
NOTICE
WARNING
WARNING

Installation & Operation Manual
4
The Armor Water Heater - How it works...
1. Stainless steel heat exchanger
Allows water to flow through specially designed
coils for maximum heat transfer, while providing
protection against flue gas corrosion. The coils are
encased in a jacket that contains the combustion process.
2. Heat exchanger access cover
Allows access to the combustion side of the heat
exchanger coils.
3. Blower
The blower pulls in air and gas through the venturi
(item 5). Air and gas mix inside the blower and are pushed into
the burner, where they burn inside the combustion chamber.
4. Gas valve
The gas valve senses the negative pressure created by the
blower, allowing gas to flow only if the gas valve is
powered and combustion air is flowing.
5. Venturi
The venturi controls air and gas flow into the burner.
6. Flue gas sensor
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.
7. Water heater outlet temperature sensor
This sensor monitors water heater outlet water temperature.
8. Water heater inlet temperature sensor
This sensor monitors return water temperature (system
return). If selected as the controlling sensor, the control
module adjusts the water heater firing rate so the inlet
temperature is correct.
9. Flow Switch
The flow switch is a safety device that ensures flow through the
heat exchanger during operation. This appliance is low mass
and should never be operated without flow. The flow switch
makes contact when flow is detected and allows the unit to
operate. If flow is discontinued during operation for any reason
the flow switch will break the control circuit and the unit will
shut down.
10. Electronic display
The electronic display consists of 7 buttons and a dual line 32-
character liquid crystal display.
11. Flue pipe adapter
Allows for the connection of the PVC vent pipe system to the
water heater.
12. Burner (not shown)
Made with metal fiber and stainless steel construction,
the burner uses pre-mixed air and gas and provides a
wide range of firing rates.
13. Water outlet
NPT water connection that supplies hot water to the
system, either 1-1/4" or 2", depending on the model.
14. Water inlet
NPT water connection that returns water from the system to
the heat exchanger, either 1-1/4" or 2", depending on the model.
15. Gas connection pipe
Threaded pipe connection, either 1/2", 3/4", or 1",
depending on the model. This pipe should be connected
to the incoming gas supply for the purpose of delivering
gas to the water heater.
16. SMART Control Module
The SMART Control responds to internal and external signals
and controls the blower, gas valve, and pumps to meet the
demand.
17. Automatic air vent
Designed to remove trapped air from the heat exchanger
coils.
18. Air intake adapter
Allows for the connection of the PVC air intake pipe to
the water heater.
19. Line voltage junction box
The junction box contains the connection points for the line
voltage power and the pump.
20. Water heater drain port
Location from which the heat exchanger can be drained.
21. Low voltage connection board
The connection board is used to connect external low voltage
devices.
22. Low voltage wiring connections (knockouts)
Conduit connection points for the low voltage
connection board.
23. Condensate drain connection
Connects the condensate drain line to a 1/2" PVC union.
24. Access cover - front
Provides access to the gas train and the heat exchanger.
25. Ignition electrode
Provides direct spark for igniting the burner.
26. Flame inspection window
The quartz glass window provides a view of the burner
surface and flame.
27. Gas shutoff valve
Manual valve used to isolate the gas valve from the gas supply.
28. High limit sensor
Device that monitors the outlet water temperature. If the
temperature exceeds its setting, it will break the control circuit,
shutting the water heater down.
29. Relief valve
Protects the heat exchanger from over pressure and
temperature conditions. The relief valve may be set at 125 or
150 PSI.
30. Flame sensor
Used by the control module to detect the presence of burner
flame.
31. Line voltage wiring connections (knockouts)
Conduit connection points for the high voltage junction box.
32. Top panel
Removable panel to gain access to the internal components.
33. Power switch
Turns 120 VAC ON/OFF to the water heater.
34. Leveling legs
Used to allow the heat exchanger to be leveled. This is needed
for the proper draining of the condensate from the combustion
chamber.
35. Air shroud
The air shroud controls air and gas flow into the burner.
36. Air pressure switch
The air pressure switch detects blocked inlet conditions.

Installation & Operation Manual
Front View - Models 150 - 285
23
8
10
13
14
15
18
20 12
25
30
29
34
35
36
Left Side (inside unit) - Models 150 - 285
1
3
4
2
27
7
28
26
21
19
16
17
5
Right Side (inside unit) - Models 150 - 285
The Armor Water Heater - How it works... (continued)
Rear View - Models 150 - 285
5
Models 150 - 285

Installation & Operation Manual
6
The Armor Water Heater - How it works...
15
18
Rear View - Model 399
18
15
27
Rear View - Model 500 Left Side (inside unit) - Model 500
Left Side (inside unit) - Model 399
Model 399
Model 500
27
4
36
35
4
36

Installation & Operation Manual
Ratings
Notes:
1. Armor water heaters require special gas venting. Use
only the vent materials and methods specified in the
Armor Installation and Operation Manual.
2. Standard Armor water heaters are equipped for
operation up to 4,500 feet with no field adjustments.
Output ratings will be reduced by 4% for each 1,000
feet above sea level up to 4,500 feet only.
3. High altitude Armor water heaters will have a high
altitude label affixed to the unit (as shown in FIG. A)
and are equipped for operation of 4,501 feet to
12,000 feet only with no field adjustments. For high
altitude models, output ratings will be reduced by 2%
for each 1,000 feet above sea level.
High altitude models have a different control module
for altitude operation, but the operation given in this
manual for standard models remains the same.
7
Maximum allowed working pressure is located on the rating plate.
Model Number
Note: Change “N” to
“L” for L.P. gas models.
CSA
Input Modulation Btu/hr Water Content
Gallons
Water
Connections
Gas
Connections
Vent/Air Size
(Note 2, 3) (Note 1)
AWN150PM 30,000 - 150,000 1.3 1-1/4" 1/2" 3"
AWN199PM 40,000 - 199,999 1.7 1-1/4" 1/2" 3"
AWN285PM 57,000 - 285,000 2.4 2" 3/4" 4"
AWN399PM 80,000 - 399,999 3.4 2" 1" 4"
AWN500PM 100,000 - 500,000 4.2 2" 1" 4"
NOTICE
Figure A High Altitude Label Location
UNIT EQUIPPED FOR
4,501 FT. TO 12,000 FT.
HIGH ALTITUDE

Installation & Operation Manual
1 Determine water heater location
8
The Armor water heater gas manifold and
controls met safe lighting and other
performance under tests specified in
ANSI Z21.10.3 – latest edition.
Failure to keep water heater area clear and
free of combustible materials, gasoline, and
other flammable liquids and vapors can
result in severe personal injury, death, or
substantial property damage.
Installation must comply with:
• Local, state, provincial, and national codes, laws, regulations,
and ordinances.
• National Fuel Gas Code, ANSI Z223.1 – latest edition.
• National Electrical Code.
• For Canada only: B149.1 Installation Code, CSA C22.1
Canadian Electrical Code Part 1 and any local codes.
Before locating the water heater, check:
1. Check for nearby connection to:
• Water piping
• Venting connections
• Gas supply piping
• Electrical power
2. Locate the appliance so that if water connections should
leak, water damage will not occur. When such locations
cannot be avoided, it is recommended that a suitable
drain pan, adequately drained, be installed under the
appliance. The pan must not restrict combustion air
flow. Under no circumstances is the manufacturer to be
held responsible for water damage in connection with
this appliance, or any of its components.
3. Check area around the water heater. Remove any
combustible materials, gasoline and other flammable
liquids.
4. The Armor water heater must be installed so that gas control
system components are protected from dripping or spraying
water or rain during operation or service.
5. If a new water heater will replace an existing water heater,
check for and correct system problems, such as:
• System leaks causing oxygen corrosion or heat exchanger
cracks from hard water deposits.
WARNING This appliance is certified as an indoor
appliance. Do not install the appliance
outdoors or locate where the appliance will
be exposed to freezing temperatures or to
temperatures that exceed 100°F.
Failure to install the appliance indoors could
result in severe personal injury, death, or
substantial property damage.
Provide clearances:
Clearances from combustible materials
1. Hot water pipes—at least 1" from combustible materials.
2. Vent pipe – at least 1" from combustible materials.
3. See FIG.’s 1-1 and 1-2 on page 9 for other clearance
minimums.
Clearances for service access
1. See FIG.’s 1-1 and 1-2 on page 9 for recommended
service clearances. If you do not provide the minimum
clearances shown, it may not be possible to service the
water heater without removing it from the space.
Closet and alcove installations
This appliance requires a special venting
system. The vent connection to the
appliance must be made with the starter
CPVC pipe section provided with the
appliance. The field provided vent fittings
must be cemented to the CPVC pipe
section. Use only the vent materials, primer
and cement specified in this manual to
make the vent connections. Failure to
follow this warning could result in fire,
personal injury, or death.
For closet and alcove installations as
shown in FIG.’s 1-1 and 1-2, CPVC vent
material must be used inside the structure.
The ventilating air openings shown in
FIG.’s 1-1 and 1-2 are required for this
arrangement. Failure to follow this
warning could result in fire, personal
injury, or death.
WARNING
WARNING
NOTICE WARNING
A closet is any room the water heater is installed in which is
less than 86 cubic feet for AWN150 models, 106 cubic feet for
AWN199 models, 120 cubic feet for AWN285 models,
165 cubic feet for AWN399 models and 191 cubic feet for
AWN500 models.
An alcove is any room which meets the criteria for a closet
with the exception that it does not have a door.
Example: Room dimensions = 4 feet long, 5 feet wide, and
9 foot ceiling = 4 x 5 x 9 = 180 cubic feet. This would be
considered a closet for a Armor Water Heater.

Installation & Operation Manual
1 Determine water heater location (continued)
9
RECOMMENDED SERVICE CLEARANCES:
FRONT - 24”
TOP - 24”
LEFT SIDE - 24”
REAR - 24”
Figure 1-2 Alcove Installation - Minimum Required Clearances
RECOMMENDED SERVICE CLEARANCES:
FRONT - 24”
TOP - 24”
LEFT SIDE - 24”
REAR - 24”
Figure 1-1 Closet Installation - Minimum Required Clearances
WARNING For closet installations, CPVC
material MUST BE used in a closet
structure due to elevated
temperatures. Failure to follow this
warning could result in fire,
personal injury, or death.
WARNING For alcove installations, CPVC
material MUST BE used in an
alcove structure due to elevated
temperatures. Failure to follow this
warning could result in fire,
personal injury, or death.

Installation & Operation Manual
1 Determine water heater location
10
Provide air openings to room:
Armor water heater alone in equipment room
1. No air ventilation openings into the equipment room are
needed when clearances around the Armor water heater are
at least equal to the SERVICE clearances shown in
FIG.’s 1-1 and 1-2. For spaces that do NOT supply this
clearance, provide two openings as shown in FIG. 1-1. Each
opening must provide one square inch free area per
1,000 Btu/hr of water heater input.
Armor water heater in same space with other gas or
oil-fired appliances
1. Follow the National Fuel Gas Code (U.S.) or CSA B149.1
(Canada) to size/verify size of the combustion/ventilation
air openings into the space.
The space must be provided with
combustion/ventilation air openings
correctly sized for all other appliances located
in the same space as the Armor water heater.
Do not install the water heater in an attic.
Failure to comply with the above warnings
could result in severe personal injury, death,
or substantial property damage.
2. Size openings only on the basis of the other appliances in
the space. No additional air opening free area is needed for
the Armor water heater because it takes its combustion air
from outside (direct vent installation).
Do not install the water heater on carpeting
even if foundation is used. Fire can result,
causing severe personal injury, death, or
substantial property damage.
If flooding is possible, elevate the water heater sufficiently to
prevent water from reaching the water heater.
Flooring and foundation
Flooring
The Armor water heater is approved for installation on
combustible flooring, but must never be installed on carpeting.
Residential garage installation
Precautions
Take the following precautions when installing the appliance in
a residential garage. If the appliance is located in a residential
garage, it should be installed in compliance with the latest
edition of the National Fuel Gas Code, ANSI Z223.1 and/or
CAN/CGA-B149 Installation Code.
• Appliances located in residential garages and in
adjacent spaces that open to the garage and are not part
of the living space of a dwelling shall be installed so that
all burners and burner ignition devices are located not
less than 18 inches (46 cm) above the floor.
• The appliance shall be located or protected so that it is
not subject to physical damage by a moving vehicle.
Vent and air piping
The Armor water heater requires a special vent system, designed
for pressurized venting.
You must also install air piping from outside to the water heater
air intake adapter. The resultant installation is direct vent
(sealed combustion). Note prevention of combustion air
contamination below when considering vent/air termination.
Vent and air must terminate near one another and may be
vented vertically through the roof or out a side wall. You may
use any of the vent/air piping methods covered in this manual.
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. The vent/air piping lengths, routing and
termination method must all comply with the methods and
limits given in this manual.
Prevent combustion air contamination
Install air inlet piping for the Armor water heater as described in
this manual. Do not terminate vent/air in locations that can
allow contamination of combustion air. Refer to Table 1A, page
11 for products and areas which may cause contaminated
combustion air.
You must pipe combustion air to the water
heater air intake. Ensure that the combustion
air will not contain any of the contaminants
in Table 1A, page 11. Contaminated
combustion air will damage the water heater,
resulting in possible severe personal injury,
death or substantial property damage. Do not
pipe combustion air near a swimming pool,
for example. Also, avoid areas subject to
exhaust fumes from laundry facilities. These
areas will always contain contaminants.
WARNING
WARNING
WARNING

Installation & Operation Manual
1 Determine water heater location (continued)
11
Products to avoid:
Spray cans containing chloro/fluorocarbons
Permanent wave solutions
Chlorinated waxes/cleaners
Chlorine-based swimming pool chemicals
Calcium chloride used for thawing
Sodium chloride used for water softening
Refrigerant leaks
Paint or varnish removers
Hydrochloric acid/muriatic acid
Cements and glues
Antistatic fabric softeners used in clothes dryers
Chlorine-type bleaches, detergents, and cleaning solvents
found in household laundry rooms
Adhesives used to fasten building products and other
similar products
Areas likely to have contaminants
Dry cleaning/laundry areas and establishments
Swimming pools
Metal fabrication plants
Beauty shops
Refrigeration repair shops
Photo processing plants
Auto body shops
Plastic manufacturing plants
Furniture refinishing areas and establishments
New building construction
Remodeling areas
Garages with workshops
Table 1A Corrosive Contaminants and Sources When removing a water heater from
existing common vent system:
Do not install the Armor water heater into
a common vent with any other appliance.
This will cause flue gas spillage or
appliance malfunction, resulting in
possible severe personal injury, death, or
substantial property damage.
Failure to follow all instructions can result
in flue gas spillage and carbon monoxide
emissions, causing severe personal injury
or death.
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.
a. Seal any unused openings in the common venting system.
b. Visually inspect the venting system for proper size and
horizontal pitch and determine there is no blockage or
restriction, leakage, corrosion, or other deficiencies,
which could cause an unsafe condition.
c. Test vent system – Insofar as is practical, close all building
doors and windows and all doors between the space in
which the appliances remaining connected to the
common venting system are located and other spaces of
the building. Turn on clothes dryers and any appliance
not connected to the common venting system. Turn on
any exhaust fans, such as range hoods and bathroom
exhausts, so they will operate at maximum speed. Do not
operate a summer exhaust fan. Close fireplace dampers.
d. Place in operation the appliance being inspected. Follow
the lighting instructions. Adjust thermostat so appliance
will operate continuously.
e. Test for spillage at the draft hood relief opening after
5 minutes of main burner operation. Use the flame of a
match or candle, or smoke from a cigarette, cigar, or pipe.
f. After it has been determined that each appliance
remaining connected to the common venting system
properly vents when tested as outlined herein, return
doors, windows, exhaust fans, fireplace dampers, and any
other gas-burning appliance to their previous conditions
of use.
g. Any improper operation of the common venting system
should be corrected so the installation conforms with the
National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or
CAN/CSA B149.1, Natural Gas and Propane Installation
Code. When resizing any portion of the common venting
system, the common venting system should be resized to
approach the minimum size as determined using the
appropriate tables in Part 11 of the National Fuel Gas
Code, ANSI Z223.1/NFPA and/or CAN/CSA B149.1,
Natural Gas and Propane Installation Code.
DANGER
WARNING

Installation & Operation Manual
2 Prepare water heater
12
Figure 2-2 Installing Propane Orifice - Models 150 - 285
Remove water heater from wood pallet
1. After removing the outer shipping carton from the water
heater, remove the parts box.
2. Remove the front door to access the lag bolts in front of the
unit (FIG. 2-1).
3. To remove the water heater from the pallet (after removing
the front door):
a. 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
jacket on the floor or pallet. Damage to the
water heater can result.
For a water heater already installed, you must
turn off gas supply, turn off power and allow
the water heater to cool before proceeding.
You must also completely test the water
heater after conversion to verify performance
as described under Start-up, Section 10 of
this manual. Failure to comply could result
in severe personal injury, death, or
substantial property damage.
For Models 150 - 399 you must install a
propane orifice to operate the Armor water
heater on propane gas. Verify when
installing that the orifice size marking
matches water heater size (Models 150 – 399,
Table 2A).
The 500 Model does not require an orifice
installation for propane operation, but it will
require a valve adjustment.
Models 150 - 285
1. Remove the top and front access covers from the unit (no
tools required for removal).
2. Remove the three screws securing the gas valve to the venturi
(FIG. 2-2).
3. Locate the propane orifice disk from the conversion kit bag.
Verify that the stamping on the orifice disk matches the
water heater size (150 – 285) (see Table 2A above).
Place the orifice into the black rubber grommet in the side
of the gas valve and secure in the valve (FIG. 2-2).
4. Reposition the gas valve against the venturi and replace the
screws (FIG. 2-2) securing the valve to the venturi.
5. After installation 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.
6. Replace the top and front access covers.
Figure 2-1 Water heater Mounted on Shipping Pallet
Gas conversions
LP Conversion Table
Model LP Orifice Stamping
150 150
199 210 / W150
285 285
399 8.0
NOTICE
WARNING
Table 2A LP Conversion Table
WARNING After converting to LP, check combustion per
the Start-up procedure in Section 10 of this
manual. Failure to check and verify
combustion could result in severe personal
injury, death, or substantial property
damage.

Installation & Operation Manual
13
2 Prepare water heater (continued)
Figure 2-3 Installing Propane Orifice - Model 399
Figure 2-5 Leveling Legs on the Water Heater
Leveling the water heater
1. Set the water heater in place and check level.
a) Adjust legs if necessary to level the water heater,
see FIG. 2-5 below.
Model 399
1. Remove the top and front access covers from the unit (no tools
required for removal).
2. Remove the three screws securing the venturi to the blower.
Note: When separating the venturi from the blower, take care
not to damage the O-ring inside the blower (FIG. 2-3).
3. Remove the four screws securing the gas valve to the venturi
(FIG. 2-3).
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 12).
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. Position
and secure the orifice in the valve as shown in FIG. 2-3.
6. Reposition the gas valve against the venturi and replace the
screws (FIG. 2-3) securing the valve to the venturi.
7. Inspect the O-ring inside the blower. Handle the O-ring with
care, do not damage. Reposition the venturi against the blower
and replace the screws securing the venturi to the blower
(FIG. 2-3).
8. After installation 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.
9. Replace the top and front access covers.
DANGER Armor 399: Inspect the O-ring when the blower
is disassembled. The O-ring must be in good
condition and must be installed. Failure to
comply will cause a gas leak, resulting in severe
personal injury or death.
Figure 2-4 Gas Valve Adjustment - Model 500
Model 500
1. Remove the top access cover from the unit (no tools
required for removal).
2. Turn the adjustment screw on the gas valve clockwise
until it stops. Then turn the adjustment screw
counterclockwise four and three quarter (4 3/4) turns
(see FIG. 2-4).
3. Use a combustion analyzer to verify CO2is within the
range of 9.6 – 10.5%. If not, adjust the screw
counterclockwise incrementally to raise CO2and
clockwise to lower CO2(FIG. 2-4).
4. 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.
5. Replace the top access cover.
WARNING After converting to LP, check combustion per
the Start-up procedure in Section 10 of this
manual. Failure to check and verify combustion
could result in severe personal injury, death, or
substantial property damage.
WARNING After converting to LP, check combustion
per the Start-up procedure in Section 10
of this manual. Failure to check and
verify combustion could result in severe
personal injury, death, or substantial
property damage.

Installation & Operation Manual
3 General venting
14
Figure 3-1 Vertical Direct Venting (Two-Pipe Vertical
Termination) - See page 24 for more details
Figure 3-2 Sidewall Direct Venting (Two-Pipe Sidewall
Termination) - See page 18 for more details
Figure 3-3 Concentric Vertical Termination - See page
26 for more details
Figure 3-4 Concentric Sidewall Termination - See page
21 for more details
Direct venting options

Installation & Operation Manual
3 General venting (continued)
15
Vent piping materials
Use only the materials listed in Table 3A
below for vent pipe, and fittings. Failure to
comply could result in severe personal
injury, death, or substantial property
damage.
Installation must comply with local
requirements and with the National Fuel Gas
Code, ANSI Z223.1 for U.S. installations or
CSA B149.1 for Canadian installations.
Table 3A Vent Pipe, and Fittings
Install vent and combustion air piping
DANGER The Armor water heater must be vented and
supplied with combustion and ventilation air
as described in this section. Ensure the vent
and air piping and the combustion air supply
comply with these instructions regarding
vent system, air system, and combustion air
quality. See also Section 1 of this manual.
Inspect finished vent and air piping
thoroughly to ensure all are airtight and
comply with the instructions provided and
with all requirements of applicable codes.
Failure to provide a properly installed vent
and air system will cause severe personal
injury or death.
All vent pipes must be glued, properly
supported, and the exhaust must be
pitched a minimum of a 1/4 inch per foot
back to the water heater (to allow drainage
of condensate).
This appliance requires a special venting
system. The vent connection to the
appliance must be made with the starter
CPVC pipe section provided with the
appliance. The field provided vent fittings
must be cemented to the CPVC pipe
section using an “All Purpose Cement”
suitable for PVC and CPVC pipe. Use only
the vent materials, primer, and cement
specified in this manual to make the vent
connections. Failure to follow this
warning could result in fire, personal
injury, or death.
WARNING
NOTICE
WARNING
WARNING For closet and alcove installations, CPVC
material MUST BE used in a closet/alcove
structure. Failure to follow this warning
could result in fire, personal injury, or death.
NOTICE
Requirements for installation in
Canada
1. Installations must be made with a vent pipe system
certified to ULC-S636.
IPEX is an approved vent manufacturer in Canada
supplying vent material listed to ULC-S636.
2. The first three (3) feet of plastic vent pipe from the
appliance flue outlet must be readily accessible for visual
inspection.
3. The components of the certified vent system must not be
interchanged with other vent systems or unlisted
pipe/fittings. For concentric vent installations, the inner
vent tube must be replaced with field supplied certified
vent material to comply with this requirement.
4. 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.
Both kits are listed to the ULC-S636 standard for use in
Canada.
All vent pipe materials and fittings must comply with the following:
Item Material Standards for installation in:
United States Canada
Vent pipe and fittings
PVC schedule 40 ANSI/ASTM D1785 CPVC and PVC venting must be
ULC-S636 Certified. IPEX is an
approved manufacturer in Canada
supplying vent material listed to
ULC-S636.
PVC-DWV ANSI/ASTM D2665
CPVC schedule 40 ANSI/ASTM F441
Pipe cement/primer
PVC ANSI/ASTM D2564 IPEX System 636
Cements & Primers
CPVC ANSI/ASTM F493
NOTICE: DO NOT USE CELLULAR (FOAM) CORE PIPE

Installation & Operation Manual
3 General venting
16
Air intake/vent connections
1. Combustion Air Intake Connector (FIG.’s 3-5 thru 3-7) -
Used to provide combustion air directly to the unit
from outdoors. A fitting is provided on the unit for final
connection. Combustion air piping must be supported
per guidelines listed in the National Mechanical Code,
Section 305, Table 305.4 or as local codes dictate.
2. Vent Connector (FIG.’s 3-5 thru 3-7) - Used to provide a
passageway for conveying combustion gases to the
outside. A transition fitting is provided on the unit for
final connection. Vent piping must be supported per the
National Building Code, Section 305, Table 305.4 or as
local codes dictate.
Combustion air piping to the outside MUST
BE used. Use of combustion air from the
room via louvers, plenums, or any other
device is not authorized.
NOTICE
3” CPVC PIPE SUPPLIED WITH
WATER HEATER MUST BE USED
FOR VENT CONNECTION
NOTE: CPVC VENT PIPE AND VENT FITTINGS MUST BE USED
IN CLOSET AND ALCOVE INSTALLATIONS.
VENT
AIR
Figure 3-5 Near Water Heater Venting Models 150 - 199
4” CPVC PIPE SUPPLIED WITH
WATER HEATER MUST BE USED
FOR VENT CONNECTION
NOTE: CPVC VENT PIPE AND VENT FITTINGS MUST BE USED
IN CLOSET AND ALCOVE INSTALLATIONS.
VENT
AIR
Figure 3-6 Near Water Heater Venting Models 285 - 399
The Armor water heater uses model specific combustion air
intake and vent piping sizes as detailed in Table 3B below.
Model Air Intake Vent
150 - 199 3 inches 3 inches
285 - 500 4 inches 4 inches
Table 3B Air Intake/Vent Piping Sizes
Increasing or decreasing combustion air or
vent piping is not authorized.
NOTICE
4" CPVC PIPE SUPPLIED WITH
WATER HEATER MUST BE USED FOR
VENT CONNECTION
NOTE: CPVC VENT PIPE AND VENT FITTINGS MUST BE USED
IN CLOSET AND ALCOVE INSTALLATIONS.
VENT
AIR
Figure 3-7 Near Water Heater Venting Model 500
Air inlet pipe materials:
The air inlet pipe(s) must be sealed. Choose acceptable
combustion air inlet pipe materials from the following list:
PVC, CPVC or ABS
Dryer Vent or Sealed Flexible Duct (not recommended for
rooftop air inlet)
Galvanized steel vent pipe with joints and seams sealed as
specified in this section.
Type “B” double-wall vent with joints and seams sealed as
specified in this section.
*Plastic pipe may require an adapter (not provided) to
transition between the air inlet connection on the appliance and
the plastic air inlet pipe.

Installation & Operation Manual
17
3 General venting (continued)
Vent, air piping and termination:
The Armor water heater vent and air piping can be installed
through the roof or through a sidewall. Follow the procedures
in this manual for the method chosen. Refer to the information
in this manual to determine acceptable vent and air piping
length.
Air contamination
Pool and laundry products and common household and hobby
products often contain fluorine or chlorine compounds. 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.
Please read the information given in Table 1A, page 11, listing
contaminants and areas likely to contain them. If contaminating
chemicals will be present near the location of the water heater
combustion air inlet, have your installer pipe the water heater
combustion air and vent to another location, per this manual.
If the water heater combustion air inlet is
located in a laundry room or pool facility, for
example, these areas will always contain
hazardous contaminants.
To prevent the potential of severe personal
injury or death, check for areas and products
listed in Table 1A, page 11 before installing
the water heater or air inlet piping.
If contaminants are found, you MUST:
• Remove contaminants permanently.
—OR—
• Relocate air inlet and vent terminations
to other areas.
Removing from existing vent
Follow the instructions in Section 1, page 11 of this manual
when removing a water heater from an existing vent system.
Vent and air piping
Vent and air system:
Installation must comply with local
requirements and with the 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).
You may use any of the vent/air piping methods covered in this
manual. Do not attempt to install the Armor water heater using
any other means.
DO NOT mix components from different
systems. The vent system could fail, causing
leakage of flue products into the living space.
Use only PVC or CPVC pipe and fittings,
with primer and cement specifically
designed for the material used.
NOTICE
WARNING
WARNING
WARNING
Model Kit Number Equivalent Vent
Length
80 - 210 CVK3003 3 feet
285 CVK3007 3 feet
399 CVK3007 5 feet
500 CVK3007 30 feet
Table 3C Equivalent Vent Lengths
The appliance output rating will reduce by
up to 1.5% for each 25 feet of vent length.
NOTICE
Minimum / Maximum allowable
combustion air and vent piping lengths
are as follows:
Combustion Air = 12 equivalent feet minimum / 100
equivalent feet maximum
Ve n t = 12 equivalent feet minimum / 100 equivalent feet
maximum
When determining equivalent combustion air and vent length,
add 5 feet for each 90° elbow and 3 feet for each 45° elbow.
EXAMPLE: 20 feet of PVC pipe + (4) 90° elbows + (2) 45°
elbows + (1) concentric vent kit (CVK3003) = 49 equivalent feet
of piping.

Installation & Operation Manual
18
4 Sidewall direct venting
Vent/air termination – sidewall
Follow instructions below when determining
vent location to avoid possibility of severe
personal injury, death, or substantial
property damage.
A gas vent extending through an exterior
wall shall not terminate adjacent to a wall or
below building extensions such as eaves,
parapets, balconies, or decks. Failure to
comply could result in severe personal
injury, death, or substantial property
damage.
Installation must comply with local
requirements and with the National Fuel Gas
Code, ANSI Z223.1 for U.S. installations or
CSA B149.1 for Canadian installations.
WARNING
WARNING
NOTICE
WARNING Do not connect any other appliance to the
vent pipe or multiple water heaters to a
common vent pipe. Failure to comply could
result in severe personal injury, death, or
substantial property damage.
Determine location
Locate the vent/air terminations using the following guidelines:
1. The total length of piping for vent or air must not exceed the
limits given in the General Venting Section on page 17 of
this manual.
2. You must consider the surroundings when terminating the
vent and air:
a. Position the vent termination where vapors will
not damage nearby shrubs, plants or air
conditioning equipment or be objectionable.
b. The flue products will form a noticeable plume as
they condense in cold air. Avoid areas where the
plume could obstruct window views.
c. Prevailing winds could cause freezing of
condensate and water/ice buildup where flue
products impinge on building surfaces or plants.
d. Avoid possibility of accidental contact of flue
products with people or pets.
e. Do not locate the terminations where wind eddies
could affect performance or cause recirculation,
such as inside building corners, near adjacent
buildings or surfaces, window wells, stairwells,
alcoves, courtyards, or other recessed areas.
WARNING Sidewall vent and air inlet terminations
must terminate in the same pressure zone.
f. Do not terminate above any door or window.
Condensate can freeze, causing ice formations.
g. Locate or guard vent to prevent condensate damage
to exterior finishes.
TO BOILER
INTAKE AIR
CONNECTION
FROM BOILER
VENT PIPE
CONNECTION
TERMINATION
PLATE
BIRD
SCREEN
GRADE OR
SNOW LINE
12”
MIN
12” MIN
15” MAX
BIRD SCREEN
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.
Figure 4-1B Alternate Sidewall Termination of Air and
Vent w/Field Supplied Fittings
WARNING
If using the alternate sidewall termination:
3. The air piping must terminate in a down-turned elbow as
shown in FIG. 4-1B. This arrangement avoids recirculation
of flue products into the combustion air stream.
4. The vent piping must terminate in an elbow pointed
outward or away from the air inlet, as shown in FIG. 4-1B.
TO BOILER
INTAKE AIR
CONNECTION
FROM BOILER
VENT PIPE
CONNECTION
VENT / AIR
TERMINATION
GRADE OR
SNOW LINE
12"
MIN
12"
MIN
TO
OVER-
HANG
POSSIBLE ORIENTATIONS
Figure 4-1A Sidewall Termination of Air and Vent
Model Kit Number Vent Size
150 - 199 KIT30045 3 inch vent
285 - 500 KIT30046 4 inch vent
Table 4A Sidewall Vent Kits

Installation & Operation Manual
19
Vent/air termination – sidewall
4 Sidewall direct venting (continued)
5. Maintain clearances as shown in FIG.’s 4-1A thru 4-3B,
pages 18 and 19. Also maintain the following:
a. Vent must terminate:
• At least 6 feet from adjacent walls.
• No closer than 12 inches below roof overhang.
• At least 7 feet above any public walkway.
• At least 3 feet above any forced air intake within
10 feet.
• No closer than 12 inches below or horizontally
from any door or window or any other gravity air
inlet.
b. Air inlet must terminate at least 12 inches above
grade or snow line; at least 12 inches below the vent
termination; and the vent pipe must not extend
more than 24 inches vertically outside the building
as shown in FIG. 4-1B.
c. Do not terminate closer than 4 feet horizontally
from any electric meter, gas meter, regulator, relief
valve, or other equipment. Never terminate above or
below any of these within 4 feet horizontally.
6. Locate terminations so they are not likely to be damaged by
foreign objects, such as stones or balls, or subject to buildup
of leaves or sediment.
ALTERNATE VENTING ARRANGEMENT
(IF SPACE PERMITS)
BIRD
SCREEN
12”
MIN
12” MIN
15” MAX
COUPLING
TO BOILER
INTAKE AIR
CONNECTION
FROM BOILER
VENT PIPE
CONNECTION
BIRD SCREEN
Figure 4-1C Alternate Venting Arrangement (if Space
Allows) w/Field Supplied Fittings
VENT / AIR
TERMINATION
12"
MIN.
12"
MIN.
12"
MIN.
Figure 4-2A Clearance to Gravity Air Inlets
Figure 4-2B Alternate Clearance to Gravity Air Inlets
w/Field Supplied Fittings
FORCED AIR
INLET
VENT / AIR
TERMINATION
7' MIN. ABOVE ANY
PUBLIC WALKWAY
IF LESS
THAN 10’
36"
MIN.
Figure 4-3A Clearance to Forced Air Inlets
Figure 4-3B Alternate Clearance to Forced Air Inlets
w/Field Supplied Fittings

Installation & Operation Manual
20
4 Sidewall direct venting
Termination and fittings
1. The air termination coupling must be oriented at least
12 inches above grade or snow line as shown in FIG. 4-1A,
page 18.
2. Maintain the required dimensions of the finished
termination piping as shown in FIG. 4-1A, page 18.
3. If using the alternate sidewall termination do not extend
exposed vent pipe outside of the building more than what is
shown in this document. Condensate could freeze and
block vent pipe.
4. PVC/CPVC terminations are designed to accommodate any
wall thickness of standard constructions per the directions
found in this manual.
Prepare wall penetrations (Alternate -
Field Supplied Option)
1. Air pipe penetration:
a. Cut a hole for the air pipe. Size the air pipe hole as
close as desired to the air pipe outside diameter.
2. Vent pipe penetration:
a. Cut a hole for the vent pipe. For either combustible
or noncombustible construction, size the vent pipe
hole with at least a 1/2 inch clearance around the vent
pipe outer diameter:
• 4½ inch hole for 3 inch vent pipe
• 5½ inch hole for 4 inch vent pipe
b. Insert a galvanized metal thimble in the vent pipe
hole as shown in FIG. 4-4B.
3. Use a sidewall termination plate as a template for correct
location of hole centers.
4. Follow all local codes for isolation of vent pipe when passing
through floors or walls.
5. Seal exterior openings thoroughly with exterior caulk.
VENT PIPING
GALVANIZED
THIMBLE
VENT CAP
AIR PIPING
WALL PLATE
VENT PLATE
Figure 4-4A Sidewall Termination Assembly
BIRD SCREEN
AIR PIPING
VENT PIPING
ELBOW
BIRD SCREEN
ELBOW
BIRD SCREEN
SIDEWALL
TERMINATION PLATE
GALVANIZED
THIMBLE
Figure 4-4B Alternate Sidewall Termination Assembly
w/Field Supplied Fittings
All vent pipes and air inlets must terminate
at the same height to avoid possibility of
severe personal injury, death, or substantial
property damage.
Multiple vent/air terminations
1. When terminating multiple Armor water heaters terminate
each vent/air connection as described in this manual
(FIG. 4-5A).
2. Place wall penetrations to obtain minimum clearance of
12 inches between edge of air inlet and adjacent vent outlet,
as shown in FIG. 4-5A for U.S. installations. For Canadian
installations, provide clearances required by 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.
WARNING
12" MIN. BETWEEN EDGE OF AIR
INLET AND ADJACENT VENT OUTLET
VENT / AIR
TERMINATION
VENT
AIR
Figure 4-5A Multiple Vent Terminations (must also
comply with Figure 4-1A)
Prepare wall penetrations
1. Use the factory supplied wall plate as a template to locate
the vent and air intake holes and mounting holes.
Air pipe penetration:
a. Cut a hole for the air pipe. Size the air pipe hole as
close as desired to the air pipe outside diameter.
Vent pipe penetration:
a. Cut a hole for the vent pipe. For either combustible or
noncombustible construction, size the vent pipe hole
with at least a 1/2 inch clearance around the vent pipe
outer diameter:
• 4½ inch hole for 3 inch vent pipe
• 5½ inch hole for 4 inch vent pipe
Drill 3/16" diameter holes for inserting the plastic anchors
into the wall.
2. Install the vent and air intake piping through the wall into
the vent plate openings. Seal all gaps between the pipes and
wall. Use RTV silicone sealant to seal the air pipe. Use the
cement/primer listed in Table 3A on page 15 to seal the vent
pipe.
3. Mount and secure the vent plate to the wall using stainless
steel screws. Seal around the plate to the wall assuring no
air gaps.
4. Assemble the vent cap to the vent plate (see FIG. 4-4A).
Insert the stainless steel screws into the vent cap screw hole
openings and securely attach the vent cap to the vent plate.
5. Seal all wall cavities.