Lochinvar ARMOR 151 - 801 User manual

Service Manual
Models: 151 - 801
This manual must only be used by a
qualified heating installer / service
technician. Read all instructions,
including this manual and the Armor
Water Heater 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.
AWII-SER Rev A

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
Display Panel Parameter Access . . . . . . . . . . . . . . . . . . . 11
Parameter Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-13
Viewable and Changeable Control Parameters . . . . . . . 14-18
2. MAINTENANCE
Maintenance and Annual Startup . . . . . . . . . . . . . . . . . . 19-23
3. TROUBLESHOOTING
Before Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Check Control Module Fuses . . . . . . . . . . . . . . . . . . . . . 24
Table 3A - Troubleshooting Chart - No Display . . . . . . . . 25
Checking Temperature Sensors . . . . . . . . . . . . . . . . . . . 26
Table 3E - Troubleshooting Chart - Noisy System . . . . . 27
Table 3F - Troubleshooting Chart - Fault Messages . . . . 28-35
Combustion Analysis Procedure . . . . . . . . . . . . . . . . . . . 36
Table 3G - Flue Products . . . . . . . . . . . . . . . . . . . . . . . . . 36
Table 3H - Troubleshooting Chart - Combustion Levels . 36
Gas Valve Adjustment Procedure . . . . . . . . . . . . . . . . . . 37-38
Revision Notes . . . . . . . . . . . . . . . . . . . . . . . . . Back Cover
Contents

Service Manual
Please read before proceeding
Installer – Read all instructions,
including this manual and the Armor
Water Heater Installation and Operation
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.
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.

4
Service Manual
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
• A: General
• B: Data Logging
• C: Functions
• D: DHW Settings
• E: Anti-Cycling
• F: Control Modes
• G: Circulation Pumps
• H: BMS
• I: 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

1 Service
Service Manual
5
NAVIGATION DIAL
(PRESS OR TURN)
RIGHT SELECT KEY
(SOFT KEY)
LEFT SELECT KEY
(SOFT KEY)
RESET KEY
The Armor water heater display
The information on the bottom of the display shows the functions of the two SELECT keys (on either corner), and the
NAVIGATION dial (in the center):
MENU = Left SELECT Key
SETPOINTS = NAVIGATION Dial - Pressing Down
SHDN = Right SELECT Key