Lochinvar Armor 100 Series User manual

Service Manual
Models: 400 - 1000
Series 100 & 101
This manual must only be used by
a qualified heating installer / service
technician. Read all instructions,
including this manual and the Armor
Installation and Operation 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.
100332297_2000589045_Rev A
LOW LEAD CONTENT

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.
CONTENTS....................................................................... 2
Hazard Definitions.............................................................. 2
PLEASE READ BEFORE PROCEEDING..................... 3
Handling Ceramic Fiber Materials...................................... 3
When servicing water heater ........................................ 3
Water heater operation................................................ 3
WHAT IS IN THIS MANUAL ........................................... 4
1. SERVICE
The Armor Water Heater Display....................................... 5
Control Inputs ............................................................... 6
Control Outputs............................................................. 7
General Operation ........................................................ 8
Sequence of Operation ...................................................... 9
Display Panel Menu Access ............................................ 10
Parameter Table.......................................................... 11-12
Initial Setup ...................................................................... 13
Viewable and Changeable Control Parameters.......... 14-22
2. MAINTENANCE
Maintenance and Annual Startup................................ 23-27
3. TROUBLESHOOTING
Before Troubleshooting.................................................... 28
Check Control Module Fuses .......................................... 28
Table 3A - Troubleshooting Chart - No Display............... 29
Checking Temperature Sensors ...................................... 30
Table 3E - Troubleshooting Chart - Noisy System .......... 31
Table 3F - Troubleshooting Chart - Fault Messages .. 32-39
Combustion Analysis Procedure ...................................... 40
Table 3G - Flue Products................................................. 40
Table 3H - Troubleshooting Chart - Combustion Levels.. 40
Gas Valve Adjustment Procedure.................................... 41
Revision Notes .................................................. Back Cover
Contents

Service Manual
Please read before proceeding
Installer – Read all instructions,
including this manual and the Armor
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 (see the
Armor Water Heater Installation and Operation
Manual).
Any claims for damage or shortage in
shipment must be filed immediately against the
transportation company by the consignee.
3
Handling ceramic fiber materials
REMOVAL OF COMBUSTION CHAMBER LINING
The combustion chamber insulation in this appliance
contains ceramic fiber material. Ceramic fibers can
be converted to cristobalite in very high temperature
applications. The International Agency for Research
on Cancer (IARC) has concluded, “Crystalline silica
in the form of quartz or cristobalite from occupational
sources is carcinogenic to humans (Group 1)”. Normal
operating temperatures in this appliance are below the
level to convert ceramic fibers to cristobalite. Abnormal
operating conditions would have to be created to convert
the ceramic fibers in this appliance to cristobalite.
The ceramic fiber material used in this appliance is
an irritant; when handling or replacing the ceramic
materials it is advisable that the installer follow these
safety guidelines.
Avoid breathing dust and contact with skin and
eyes.
• Use NIOSH certified dust respirator (N95).
This type of respirator is based on the OSHA
requirements for cristobalite at the time this
document was written. Other types of
respirators may be needed depending on the job
site conditions. Current NIOSH recommendations
can be found on the NIOSH website at
http://www.cdc.gov/niosh/homepage.html.
NIOSH approved respirators, manufacturers, and
phone numbers are also listed on this website.
• Wear long-sleeved, loose fitting clothing, gloves,
and eye protection.
Apply enough water to the combustion chamber
lining to prevent airborne dust.
Remove the combustion chamber lining from the
water heater and place it in a plastic bag for disposal.
Wash potentially contaminated clothes separately
from other clothing. Rinse clothes washer
thoroughly.
NIOSH stated First Aid.
Eye: Irrigate immediately.
Breathing: Fresh air.
󰖱WARNING NOTICE
󰖱WARNING
When servicing 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.
Water Heater Installation and Operation Manual, before
installing. Perform steps in the order given.
User – This manual is for use only by a qualified heating
installer/service technician. Refer to the Armor User’s
Information Manual for your reference.
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.

4
What is in this manual?
Service
The Armor water heater display
• Display panel readout, buttons and their functions
Control module inputs
• Control module inputs and options
Control module outputs
• Control module outputs and options
General
• How the water heater operates
• How the control module operates
• Access modes -- user and installer
•Sequence of operation -- Water Heating
Control panel menu access
• Accessing programming mode and locating menus
(See separate guide covering the PC interface.)
Control panel parameter access
• Accessing and changing parameters from the display panel
Quick start information -- parameter table
• An index of available adjustments and readouts, where to
access them and where to find detailed information.
Armor water heater operation
• General
• Data Logging
• Functions
• DHW Settings
• Anti-Cycling
• Control Modes
• Circulation Pumps
• BMS
• Service Notification
Maintenance
• Service and maintenance schedules
• Address reported problems
• Inspect water heater area and water heater interior
• Clean condensate trap
• Check all piping for leaks
• Check air openings
• Flue vent system and air piping
• Check water system
• Check water heater relief valve
• Inspect ignition electrode
• Check ignition ground wiring
• Check all water heater wiring
• Check control settings
• Perform start-up and checks
• Check burner flame
• Check flame signal
• Check flue gas temperature
• General maintenance
• Review with owner
• Cleaning the water heater heat exchanger
• Oiled bearing circulators
Troubleshooting
• Troubleshooting table - No display
• Checking temperature sensors
• Sensor tables
• Troubleshooting table - Fault messages displayed on the
water heater interface
• Combustion analysis procedure
• Gas valve adjustment procedure
Service Manual

1 Service
5
The Armor water heater display
Service Manual
HOME
VIEW
SETUP
INFORMATION
SETTINGS

1 Service
6
GAS PRESSURE SWITCH
DHW THERMOSTAT
FLOW SWITCH
TANK SENSOR
SEQUENCER / BUILDING
MANAGEMENT SYSTEM
LOW VOLTAGE
CONNECTION
BOARD
INLET TEMPERATURE
SENSOR
OUTLET TEMPERATURE
SENSOR
FLUE GAS SENSOR
LOUVER PROVING SWITCH
FLAME SENSOR
LOW WATER CUTOFF
BLOCKED DRAIN SWITCH
DISPLAY PANEL
SMART SYSTEM
CONTROL BOARD
AIR PRESSURE SWITCH
Control inputs
Service Manual

7
LOW VOLTAGE
CONNECTION
BOARD
SMART SYSTEM
CONTROL BOARD
ALARM BELL
LOUVER RELAY
RUN TIME CONTACTS
SEQUENCER / BUILDING
MANAGEMENT SYSTEM
WATER HEATER PUMP
IGNITOR
BLOWER
GAS VALVE
DI SPL AY PANE L
BUILDING RECIRCULATION
PUMP
Control outputs
1 Service (continued)
Service Manual

1 Service
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General Operation
How the water heater operates
The Armor water heater uses an advanced stainless steel heat
exchanger and an electronic control module that allows fully
condensing operation. The blower pulls in gas and air and
pushes flue products out of the water heater through the heat
exchanger and flue piping. The control module regulates blower
speed to control 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.
Sequence of operation
Table 1A shows control module normal sequences of operation
for water heating operation.
Access modes
User
The USER can set the tank set point, turn the unit OFF and ON,
and set up WiFi.
Installer
Most parameters are available only to the INSTALLER,
accessible only by entering the installer password (5309) when
selecting the Setup Section.
NOTE: The password will timeout after an hour from entry.
Service Manual

9
Table 1A Sequence of operation
1 Service (continued)
Service Manual
1. Upon a call for heat, the control turns on the DHW pump.
2. The control confirms that the low water cutoff / flow switch contacts are closed and energizes the louvers (optional).
3. The control confirms that the gas pressure switch, blocked drain switch, limits, louver proving switch (optional), and
contacts close. The Pre-Purge cycle begins.
4. The control confirms the blower comes up to the desired speed.
5. Once the Pre-Purge cycle is complete, the control lowers the blower speeds, initiates sparking of the ignition
electrode, and opens the gas valve.
6. After a short wait, the control stops sparking and checks for the presence of flame current through the flame sense
electrode.
7.
If the ame is not detected aer the sparking ends, the control will perform a postpurge, then start another prepurge
cycle and try to light the burner again. On the 500 and larger models, the control will lock out if this second attempt
also fails. On the 400 model, the control will perform a total of 4 attempts before locking out. Once the control has
locked the unit out, the RESET button will need to be pressed on the touch screen LCD.
8.
If the control detects flame current, the control will hold the blower speed constant for a few seconds to allow the
flame to stabilize, then begin modulating the firing rate in order to maintain the controlling sensor to the desired set
point temperature.
9. Once the DHW call for heat is satisfied, the control will turn off the gas valve and begin the Post-Purge cycle. Any
pumps that are running will begin their respective Pump Delay cycles.
10. At the end of the Post-Purge cycle, the louver relay contacts will de-energize.
11. At the end of the Pump Delay cycle(s), the pump(s) will be turned off.

1 Service
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Display panel menu access
Service Manual

1 Service
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Parameter table
Table 1B This table lists SMART TOUCH control module parameters and where to access them
Menu Description
User Access Installer Access
Display Modify Display Modify
Time and Date Yes Yes Yes Yes
Software Version (read only) No No Yes No
Temperature Units (ºC/ºF) Yes Yes Yes Yes
DHW Night Setback Offset No No Yes Yes
DHW Night Setback On Times No No Yes Yes
DHW Night Setback Off Times No No Yes Yes
Display Timeout No No Yes Yes
Reset Log Errors No No Yes Yes
Service Mode Delay No No Yes Yes
Tank Set Point Yes Yes Yes Yes
Tank Set Point Offset Yes Yes Yes Yes
Tank Set Point Differential No No Yes Yes
Tank Minimum Set Point No No Yes Yes
Tank Maximum Set Point No No Yes Yes
Anti-Cycling Time No No Yes Yes
Anti-Cycling Override Differential No No Yes Yes
Ramp Delay No No Yes Yes
Ramp Setting No No Yes Yes
GENERAL
DATA
LOGGING
FUNCTIONS
DHW SETTINGS
ANTI-
CYCLING
Service Manual

1 Service (continued)
Menu Description
User Access Installer Access
Display Modify Display Modify
BMS Tstat Input No No Yes Yes
BMS No No Yes Yes
ModBus No No Yes Yes
ModBus T/O No No Yes Yes
Cascade Address No No Yes Yes
Cascade Type No No Yes Yes
Max Cascade Set Point No No Yes Yes
Min On/Off Time No No Yes Yes
Min Next On Time No No Yes Yes
Water Heater Size No No Yes Yes
DHW Pump Delay No No Yes Yes
DHW Pump Anti-Seize Delay No No Yes Yes
BMS Type (Power / Set Point) No No Yes Yes
Volts at Min No No Yes Yes
Volts at Max No No Yes Yes
Rate at Min Volts No No Yes Yes
Rate at Max Volts No No Yes Yes
Set Point at Min Volts No No Yes Yes
Set Point at Max Volts No No Yes Yes
On Volts No No Yes Yes
Off Differential Volts No No Yes Yes
Service Notification Months No No Yes Yes
Service Notification Running Time No No Yes Yes
Service Notification Cycles No No Yes Yes
Reset Maintenance Reminder No No Yes Yes
Installer Name and Phone Number No No Yes Yes
CONTROL MODES
CIRCULATION
PUMPS
12
SERVICE
BMS
NOTIFICATION
Parameter table
Table 1B (continued from previous page) This table lists SMART TOUCH control module parameters and where
to access them
Service Manual

1 Service
13
Service Manual
Initial Setup Screen
Figure 1-1 Settings
Initial Setup
Clock and Date
The control uses an internal clock for the night setback
feature and for logging of events. For these features to work
correctly, the clock must be set when the appliance is first
installed or anytime the appliance has been powered off for
more than four (4) hours. This parameter must be accessed
to set the clock. If the unit is connected to the internet, the
time will adjust based on the time zone selected.
Temperature units (°C / °F)
The control can be configured to display temperature in
either °C or °F.
Set clock
The SMART TOUCH 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 appliance is installed and anytime the
appliance has been powered off for more than four (4) hours.
Use the following procedure to set the clock:
1. Press the SETTINGS button under the Lochinvar logo
(see FIG. 1-1).
2. Press the SET button across from the date and time (see
FIG. 1-1).
3. Proceed to set the date, time, and time zone.
NOTE: Automatic Time Zone will not work.
4. Temperature units and WiFi may also be set here. These
items may be used to automatically sync the time.
5. Press the Home, View, or Back button to exit.

1 Service
Service Manual
14
Viewable and changeable control parameters
CAUTION Before changing parameters, note the settings so that the unit can be returned to its original operating
parameters.
Figure 1-2 Set Points HW Screen
Set Point Screens

1 Service
Service Manual
15
Figure 1-3 HW Night Setback
Domestic Hot Water (DHW) Night Setback On and
Off Times
This is the time in which the Night Setback Offset becomes
active. There are 7 start times and 7 stop times each for the
DHW night setback feature. The DHW Night Setback On
Times may be set to any time within a 7-day week. These
settings are referred to as triggers. Multiple start or stop
triggers may be set within a single day, if desired. When a start
trigger and a stop trigger are set to the same time, the stop
trigger has priority. The installer may adjust the DHW start
triggers in the DHW Night Setback On Times parameter. This
screen shows the start trigger number, the day of the week, and
the time of day.
Domestic Hot Water (DHW) Night Setback Off Times
The stop triggers for the DHW night setback feature can be
adjusted by accessing DHW Night Setback Off Times parameter.

1 Service (continued)
16
Tank Set Point Offset
The tank set point offset measures how far the actual temperature
must go above the set point before the call for heat ends (the
water heater will turn off). This parameter can be changed by
the installer by accessing the Tank Set Point Offset parameter.
The temperature range of this parameter is 0°F (0°C) to 10°F
(30°C). The default value is 4°F (6°C).
Tank Set Point Differential
When a tank sensor is installed, the tank temperature must
drop this amount below the tank set point (DHW Tank Set
point parameter) before the water heater turns back on. The
installer can adjust this setting by accessing the Tank Set point
Differential parameter. The minimum setting is 0° (0°C), and
the maximum is 40°F (22°C). The default setting is 6°F (3°C).
Tank Minimum Set Point
This setting controls the minimum tank set point for the tank
temperature. The installer can adjust this by accessing the Tank
Minimum Set point parameter. The minimum setting is 60°F
(16°C) and the maximum setting is the maximum tank set point
(Tank Maximum Set point parameter). The default value is 60°
(16°C).
Tank Maximum Set Point
This setting controls the maximum tank set point for the tank
temperature. The installer can adjust this by accessing the Tank
Maximum Set point parameter. The minimum setting is the
minimum tank set point (Tank Minimum Set point parameter)
and the maximum setting is 185°F (85°C). The default value is
140°F (60°C).
Display Timeout
This is the time in which the display remains illuminated. The
range is 10 seconds to 10 minutes. The default is 3 minutes.
Data Logging
Reset log errors
The reset log errors function clears the last 10 errors log.
Functions
Service Mode Delay
By accessing the Service Maintenance screen from the Settings
menu, the control can be placed in Service Mode. This will
override all other heat demands. The Service Mode allows
the installer to set the unit to any firing rate for the purpose of
combustion analysis. The delay sets the length of time the water
heater will stay in the Service Mode if no keys have been pressed
before going back to its original state. This parameter can only
be changed by the installer by accessing the Service Mode Delay
parameter. The time range of this parameter is 1 to 10 minutes.
The default value is 10 minutes.
DHW Settings
DHW Tank Set Point
By installing a tank sensor, the SMART TOUCH control can
perform the tank thermostat function. The SMART TOUCH
control automatically detects the presence of this sensor, and
generates a DHW call for heat when the tank temperature
drops below the tank set point differential (Tank Set point
Differential parameter), and finishes the call for heat when the
tank temperature reaches tank set point + offset. This parameter
can be changed by the installer by accessing the DHW Tank Set
point parameter. The temperature range of this parameter tank
minimum set point to tank maximum set point. The default
value is 125°F (52°C).
Service Manual

Ramp Delay (Enable / Disable)
This parameter allows the installer to enable or disable the
DHW ramp delay. The default setting is disabled.
Ramp Settings
The SMART TOUCH control can be programmed to limit
the firing rate for a fixed period of time at the start of a DHW
demand. There are six (6) possible limits, each with their own
time delay. The first limit applies as soon as the burner starts.
Once its time delay expires, the second limit is applied and its
timer begins. The control steps through these limits until the
6th (sixth) limit expires. Note, however, that the 6th limit will
also limit the rate for the rest of that heat demand. The installer
can adjust the firing limits and time delays by accessing the
Ramp Delay Screen. The screen will show the step number, the
time delay for that step and the limit value corresponding with
that step.
17
1 Service
Service Manual
Figure 1-4 Ramp Delay Interval
Anti-Cycling
Anti-Cycling Time
Once a DHW demand has been satisfied, a set amount of time
must elapse before the control will respond to a new DHW
demand. The control will block the new heat demand and anti-
cycling will be shown in the display until the time has elapsed
or the water temperature drops below the Anti-Cycling Override
Differential parameter. This parameter can be changed by the
installer by accessing the Anti-Cycling Time parameter. The
time range for this parameter is 1 minute to 10 minutes. The
default value is 1 minute.
Anti-Cycling Override Differential
The control will bypass the anti-cycling time if the inlet water
temperature drops too much. The control will use the inlet
water temperature the water heater was at when it shut off as
the starting point. If the inlet temperature drops below the
temperature parameter the control will abort anti-cycling and
allow the water heater to fire. This parameter can be changed by
the installer by accessing the Anti-Cycling Override Differential
parameter. The temperature range of this parameter is 0°F (0°C)
to 54°F (30°C). The default value is 10°F (6°C).

18
1 Service (continued)
Control modes
BMS Thermostat Input
When controlling the water heater through the 0 - 10V BMS
input or through ModBus, the water heater can be enabled one
of two ways. With the BMS Thermostat Input parameter set to
ACTIVE, the water heater will be enabled by closing the tank
thermostat input. When set to INACTIVE, the water heater
will be enabled by the voltage level on the 0 - 10V input (in the
case of 0 - 10V BMS control), or the 0 - 10V input value received
through ModBus. The default value is INACTIVE.
BMS
The set point or modulation of the water heater may be
controlled through the 0 - 10V BMS input or through ModBus.
When the BMS parameter is set to INACTIVE, the 0 - 10V
input will be ignored. When set to ACTIVE, the set point or
modulation will be controlled by the voltage on the 0 - 10V
input (in the case of 0 - 10V BMS control), or the 0 - 10V
input value received through ModBus. The default value is
INACTIVE.
ModBus
When BMS is set to ACTIVE (see BMS) and the water heater
is being controlled through ModBus, set ModBus parameter to
ACTIVE. Otherwise, set the ModBus parameter to INACTIVE.
Note that the water heater can still be monitored by ModBus
with this parameter set to INACTIVE. The default value is
INACTIVE.
ModBus T/O
The ModBus T/O is the amount of time the unit controls will
wait to receive a communication string from the BMS controller
before reverting back to its own internal parameters. This
parameter is adjustable by the installer by accessing the ModBus
T/O parameter. The adjustment range of this parameter is 5
seconds to 2 minutes. The default value is 10 seconds.
Cascade Address
The water heater designated as the Leader needs to be
programmed with address 0. All the Member water heaters
require addresses from 1 to 7, and the addresses must be
different for each Member. The addresses can be in any order,
regardless of the order in which the units are wired together.
This parameter is adjustable by the installer by accessing
the Cascade Address parameter. The tank sensor must be
connected to the Leader water heater. The default address is 1.
Cascade Type
There are two (2) options for the way a Cascade divides the
load between its heaters. The first is Lead/Lag, designated as
L/L in the menu. This method is used when it is desired to
have the least amount of total flow through the water heaters.
This method will modulate the last two (2) water heaters.
This provides for smooth transitions when a water heater
turns on or off. When the last water heater reaches 100%
and the calculated load is still increasing, it will start the next
water heater at 20% and reduce the previous water heater to
80%, thus eliminating the sudden jump in total output of the
Cascade. When the calculated load is decreasing and the last
water heater gets down to 20% fire, it will hold it there and
start lowering the firing rate on the next-to-last water heater.
When the next-to-last water heater reaches 20%, it will turn the
last water heater off and raise the rate of the next-to-last water
heater to 40%, thus eliminating the sudden drop in total output
of the Cascade.
The other Cascade divider method is Efficiency Optimization,
designated as EFF in the menu. This method is used, as the
name implies, when it is desired to have the most efficient
system. When the first water heater reaches a certain rate
(default = 90%), it lowers its rate to 45% and turns on the next
water heater at 45%. The two (2) water heaters then modulate
at the same rate.
As the calculated load increases further and both water heaters
ramp up to 90%, it lowers the rate of the first two (2) water
heaters to 60% and brings the next water heater on at 60%.
The three (3) water heaters then modulate together. As the
calculated load decreases, the water heaters will reach a lower
threshold (default = 30%), at which time the last water heater
(the third in our example) will turn off and the Cascade will
increase the rates of the remaining water heaters to provide the
equivalent total output as before ((3 x 30%) / 2 = 45% in our
example).
Efficiency optimization is automatically selected when heaters
of different sizes are programmed into the Leader water heater
(see Cascade Member Size Screen on page 20).
Service Manual

1 Service
19
Maximum Cascade Set Point
This parameter determines the set point used by the individual
water heaters in a Cascade. When a water heater is commanded
to fire by the Leader water heater, it will attempt to achieve
this temperature at its outlet. The Leader water heater will
limit the modulation of the water heaters in order to hold the
temperature at the tank sensor to the user set point. If any of the
water heater outlet temperatures reach the maximum cascade
set point, the water heater will then modulate down on its own
in order to keep its outlet temperature within the maximum
cascade set point. Therefore, this parameter can be used to limit
the outlet temperatures of all the water heaters in a Cascade.
This parameter is adjustable by the installer by accessing the
Maximum Cascade Set Point parameter. The temperature
range of this parameter is 32° (0°C) to 190°F (88°C). The
default maximum cascade set point is 185°F (85°C).
Minimum On/Off Time
In order to prevent units in a Cascade from short cycling,
this parameter defines the minimum ON and OFF time for
each unit. The installer can adjust this time by accessing the
Minimum On/Off Time parameter. The minimum setting is 0
seconds and the maximum setting is 10 minutes. The default
is 30 seconds.
Service Manual
Figure 1-5 Cascade Setup Screen
Minimum Next On Time
In order to reduce the risk of temperature overshoot with a
Cascade, this parameter defines the minimum time delay from
starting one unit until the next unit may be started. The installer
can adjust this time delay by accessing the Minimum Next On
Time parameter. The minimum setting is 0 minutes and the
maximum setting is 10 minutes. The default is 60 seconds.

Figure 1-6 Cascade Leader Setup
Figure 1-7 Cascade Member Size Screen
1 Service
Service Manual
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