Lochinvar Armor 101 Series Service Manual Download Page 1 | Manualshive

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Lochinvar Armor 101 Series Service Manual Download Page 1

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

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Summary of Contents for Armor 101 Series

Page 1: ...n 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 ...

Page 2: ...on 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 ...

Page 3: ... 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...

Page 4: ...ion 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...

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

Page 6: ...ILDING 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 ...

Page 7: ...T SYSTEM CONTROL BOARD ALARM BELL LOUVER RELAY RUN TIME CONTACTS SEQUENCER BUILDING MANAGEMENT SYSTEM WATER HEATER PUMP IGNITOR BLOWER GAS VALVE DISPLAY PANEL BUILDING RECIRCULATION PUMP Control outputs 1 Service continued Service Manual ...

Page 8: ...ontrol 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 t...

Page 9: ...ng 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 ...

Page 10: ...1 Service 10 Display panel menu access Service Manual ...

Page 11: ...etback 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 Over...

Page 12: ...es 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 Mainten...

Page 13: ...he 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 th...

Page 14: ...ual 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 ...

Page 15: ...ings 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 ...

Page 16: ...mum 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 ...

Page 17: ...ling 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 acc...

Page 18: ...meter 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 T...

Page 19: ...justable 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...

Page 20: ...Figure 1 6 Cascade Leader Setup Figure 1 7 Cascade Member Size Screen 1 Service Service Manual 20 ...

Page 21: ...set by the Rate at Maximum Volts parameter The minimum value is the Rate at Minimum Volts setting and the maximum is 100 The default value is 100 Set Point at Minimum Volts When programmed for BMS control through the 0 10V BMS input or through ModBus and the BMS Type is programmed as SETPOINT the set point represented by the Volts at Minimum parameter is set by the Set Point at Maximum Volts param...

Page 22: ...screen will appear informing the installer that maintenance is required Maintenance Notice By Running Hours When the appliance control determines that a scheduled service is due based on the hours of actual operation the appliance display will turn yellow and a new status screen will appear informing the installer that maintenance is required Maintenance Notice By Cycles When the appliance control...

Page 23: ...r Installation and Operation Manual Flame inspection stable uniform Flame signal at least 10 microamps at high fire Clean the heat exchanger if flue temperature is more than 54 F above return water temperature Check Delta T Temperature Rise If combustion or performance indicate need Clean heat exchanger Remove and clean burner using compressed air only Clean the blower wheel ANNUAL START UP Owner ...

Page 24: ...water and gas piping and verify to be leak free 2 Look for signs of leaking lines and correct any problems found 3 Check gas line using the procedure found in the Gas Connections section of the Armor Water Heater Installation and Operation Manual Check all piping for leaks The condensate trap must be filled with water during all times of water heater operation to avoid flue gas emission from the c...

Page 25: ...proceeding further Safety relief valves should be re inspected AT LEAST ONCE EVERY THREE YEARS by a licensed plumbing contractor or authorized inspection agency to ensure that the product has not been affected by corrosive water conditions and to ensure that the valve and discharge line have not been altered or tampered with illegally Certain naturally occurring conditions may corrode the valve or...

Page 26: ...the Armor Water Heater Installation and Operation Manual 2 Verify cold fill pressure is correct and that operating pressure does not go too high Check burner flame 1 Inspect flame through observation window 2 If the flame is unsatisfactory at either high fire or low fire turn off water heater and allow water heater to cool down Remove the burner and clean it thoroughly using a vacuum cleaner or co...

Page 27: ...e any solvent 7 Brush the heat exchanger while dry using a nylon bristle brush Caution DO NOT use a metal brush Re vacuum the heat exchanger 8 Finish cleaning using a clean cloth dampened with warm water Rinse out debris with a low pressure water supply 9 Allow the heat exchanger to thoroughly dry 10 Remove the field supplied rear refractory cover from the back of the combustion chamber of the hea...

Page 28: ...imum 4 inches w c natural 8 inches w c LP with gas flowing verify during water heater startup Check control module fuses ALWAYS check control module fuses before replacing control module or any major components blower etc If one of these fuses is blown it can prevent the control module or other components from operating 1 Turn OFF power to the water heater at the external line switch 2 Remove top ...

Page 29: ...ntrol board Blown fuse Replace fuse F3 on the main control board see page 25 of this manual No Burner Operation Main control board temperature set point satisfied Review temperature setting Remote thermostat satisfied Review remote thermostat setting Unit locked out on fault Consult display for specific fault Refer to fault descriptions on pages 29 36 of this manual for corrective actions Unit Doe...

Page 30: ...d as S1a S1b outlet sensor and S3a S3b flue sensor Please reference the wiring diagram in the Armor Water Heater Installation and Operation Manual for correct terminal location S1a Wire Color R BK and Y S1b Wire Color G and Y Temperature Resistance Temperature Resistance Temperature Resistance Temperature Resistance 50 19 553 158 2 004 50 40 030 158 3 478 68 12 690 176 1 464 68 25 030 176 2 492 86...

Page 31: ...ater Heater Installation and Operation Manual Dirty damaged burner Refer to page 27 in this manual for the burner removal and inspection procedure Clean or replace the burner as necessary Low water flow through the heat exchanger Refer to the System Piping section of the Armor Water Heater Installation and Operation Manual for typical flow rates Air in the piping system Properly purge all air from...

Page 32: ...ot installed Blown fuse Replace fuse F2 on the control board see page 28 of this manual Blocked Drain SW will require a manual reset once condition has been corrected Press the RESET button on the SMART TOUCH display to reset The blocked drain switch has detected excessive condensate build up inside the unit Check condensate tube from unit to floor drain for proper installation and obstructions In...

Page 33: ...e the condition has been corrected Press the RESET button on the SMART TOUCH display to reset The unit has failed to prove main burner ignition after four 4 attempts AWH0400 or two 2 attempts AWH0500 1000 Inspect spark electrode and associated wiring for damage and connection Reference this manual for removal and cleaning procedures Replace if necessary Check for proper electrical grounding of the...

Page 34: ...gas supply Verify that the plastic hose from the gas valve to the air inlet is connected and is not damaged Verify that the vent air intake pipes are installed correctly and there are no obstructions Check for 24 VAC to the gas valve at the 2 pin connection on the side of the main control board during the ignition attempt If no voltage is present replace the main control board If 24 VAC is present...

Page 35: ...eplace the pump If the system pump is a variable speed pump ensure that the system flow is not less than the water heater flow If operating on something other than an outlet sensor check temperature setting of the main control board If the manual reset high limit has tripped check setting of the device Check resistance of water sensors and compare to Table B of this manual Replace sensor if necess...

Page 36: ...an High OR Fan Speed High will require a manual reset once the condition has been corrected Press the RESET button on the SMART TOUCH display to reset The actual fan RPM is 30 higher than what is being called for Vent air intake lengths exceed the maximum allowed lengths Refer to the General Venting section of the Armor Water Heater Installation and Operation Manual for proper lengths Check for ob...

Page 37: ... exchanger Inspect the flue sensor and associated wiring Measure the resistance of the flue sensor and compare to Table 3D of this manual Replace the sensor if necessary Verify that the vent air intake pipes are properly installed and that there are no obstructions Replace the main control board Scaling has reduced water flow Deliming may be required Delta T High The temperature rise across the he...

Page 38: ...oo often Check set point of the external control Check the wiring between the external control and the unit Replace the control Service Blk While the unit is in Service Mode the outlet temperature has exceeded 185 F Establish a heating load to remove the heat from the water heater loop Verify that the system is full of water and that all air has been properly purged from the system Verify that the...

Page 39: ... the transformer Watch Dog Error The main control board has detected an internal fault Replace the main control board Write EEProm The main control board has detected an internal fault Replace the main control board CRC Parameters The main control board has detected an internal fault Replace the main control board No Error Stored The main control board has detected an internal fault Replace the ma...

Page 40: ...ft side of the screen Enter the installer password 5 Select the Service Maintenance Screen The tabs will scroll up and down to reveal more options See this manual for more detailed information 6 Insert the probe from a combustion analyzer into the hole left by the removal of the flue temperature sensor Table 3G Flue Products Chart 7 Once the water heater has modulated up to full fire measure the c...

Page 41: ...eacombustionanalyzertoverifyCO2 iswithintherange of 9 4 10 4 If not adjust the screw counterclockwise incrementally to raise CO2 and clockwise to lower CO2 FIG 3 2 and 3 3 4 Replace the gas valve cover and access covers 5 Replace the front access panel removed in Step 1 and resume operation DIR 2000582949 00 DIR 2000582949 00 DIR 2000582949 00 DIR 2000582949 00 ALLEN WRENCH ADJUSTMENT SCREW Figure...

Page 42: ...NOTES 42 Service Manual ...

Page 43: ...Service Manual 43 NOTES ...

Page 44: ...ARM SER 01 CP 2M 01 06 Revision Notes Revision A PCP 3000042688 CN 500030426 initial release 100332297_2000589045_Rev A 11 20 ...

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