Lochinvar Knight 151 Service Manual Download Page 1

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Outdoor Armor

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 Outdoor
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.

OAW-SER Rev C

Summary of Contents for Knight 151

Page 1: ...cian Read all instructions including this manual and the Outdoor 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 OAW SER Rev C ...

Page 2: ...nce 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 Outdoor Armor Water Heater Display 5 Control Inputs 6 Control Outputs 7 General Operation 8 Sequence of Operation 9 Display Panel ...

Page 3: ... 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 r...

Page 4: ...eneral 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 igni...

Page 5: ...ormation 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 Outdoor Armor Water Heater Service Manual ...

Page 6: ...EQUENCER 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 PC INTERFACE SMART SYSTEM CONTROL BOARD AIR PRESSURE SWITCH O TEMP HEAT EXCHANGER SWITCH DOOR TEMPERATURE SWITCH ...

Page 7: ...OL BOARD ALARM BELL RUN TIME CONTACTS SEQUENCER BUILDING MANAGEMENT SYSTEM WATER HEATER PUMP IGNITOR BLOWER GAS VALVE DISPLAY PANEL PC INTERFACE BUILDING RECIRCULATION PUMP Control outputs 1 Service continued Outdoor Armor Water Heater Service Manual ...

Page 8: ...n adjust tank target temperatures by pressing the NAVIGATION dial when SETPOINTS is flashing at the bottom of the display The date and time and the temperature units can also be changed Installer Most parameters are available only to the installer accessible by entering the installer password 5309 Saving parameters reference the Parameter Table Table 1D on pages 12 and 13 of this manual Please not...

Page 9: ...gain On the 501 and larger models the control will lock out if this second attempt also fails On the 400 and smaller models the control will perform a total of 4 attempts before locking out 6 If flame is detected it holds the firing rate steady for a few seconds to let the flame stabilize then it begins to modulate the firing rate based on a set point or some other command such as a 0 10V BMS sign...

Page 10: ... 5 seconds Rotate the NAVIGATION dial clockwise until 5 is displayed first digit on the left Press the NAVIGATION dial to select the next digit Rotate the NAVIGATION dial clockwise until 3 is shown in the display Press the NAVIGATION dial 2 times to move to the last digit Rotate the NAVIGATION dial counterclockwise until 9 is displayed SAVE Press the RIGHT SELECT soft key SAVE Rotate the NAVIGATIO...

Page 11: ...tering the installer access code Rotate the NAVIGATION dial counterclockwise until the arrow is next to DHW SETTINGS Press the NAVIGATION dial one time Rotate the NAVIGATION dial counterclockwise until the arrow is next to TANK MIN SETPT Press the NAVIGATION dial one time Rotate the NAVIGATION dial to the desired temperature SAVE Press the RIGHT SELECT soft key SAVE one time EXIT Press the LEFT SE...

Page 12: ...ight Setback On Times 14 No No Yes Yes DHW Night Setback Off Times 14 No No Yes Yes Display Timeout 15 No No Yes Yes Reset Log Errors 15 No No Yes Yes Service Mode Delay 15 No No Yes Yes Tank Set Point 15 Yes Yes Yes Yes Tank Set Point Offset 15 Yes Yes Yes Yes Tank Set Point Differential 15 No No Yes Yes Tank Minimum Set Point 15 No No Yes Yes Tank Maximum Set Point 15 No No Yes Yes Anti Cycling ...

Page 13: ...Min 17 No No Yes Yes Volts at Max 17 No No Yes Yes Rate at Min Volts 17 No No Yes Yes Rate at Max Volts 18 No No Yes Yes Set Point at Min Volts 18 No No Yes Yes Set Point at Max Volts 18 No No Yes Yes On Volts 18 No No Yes Yes Off Differential Volts 18 No No Yes Yes Service Notification Months 18 No No Yes Yes Service Notification Running Time 18 No No Yes Yes Service Notification Cycles 18 No No ...

Page 14: ... 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 1...

Page 15: ...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 pressing the pin button on the front of the display for five 5 seconds the control will be placed in Service Mode This will override all other heat demands The Service Mode allows the installer to set th...

Page 16: ...nk 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...

Page 17: ...s shown Press the RIGHT SELECT SAVE key 3 Rotate the NAVIGATION dial to select the address of the next boiler in the Cascade Repeat Step 2 4 Once the size of the last boiler in the Cascade has been entered and saved press the LEFT SELECT EXIT key to return to the Control Modes menu 5 If no other parameters are to be adjusted press the RIGHT SELECT HOME key to save the new settings and return to th...

Page 18: ...VIGATION dial until the back arrow character is displayed and press the NAVIGATION dial 4 When finished press the RIGHT SELECT SAVE key to return to the previous menu Please note that the brackets denote screen status NOTICE Rate at Maximum Volts When programmed for BMS control through the 0 10V BMS input or through ModBus and the BMS Type is programmed as POWER the modulation percentage represent...

Page 19: ...ication per Section 7 in the Armor Outdoor 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 Clea...

Page 20: ...ration Manual If any of these are present in the water heater intake air vicinity they must be removed Inspect water heater interior 1 Remove the front access cover and inspect the interior of the water heater 2 Vacuum any sediment from inside the water heater and components Remove any obstructions Clean condensate trap 1 Inspect the condensate drain line condensate PVC fittings and condensate tra...

Page 21: ... before 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 ...

Page 22: ...ration 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 compressed air Do not use compressed air to c...

Page 23: ...ly use the kit provided brush or an equivalent replacement nylon brush CAUTION 5 Remove the condensate hose from the heat exchanger end Connect a field supplied 3 4 diameter hose to a drain pan Using field supplied means cover the refractory in the back of the combustion chamber of the heat exchanger 6 Use a vacuum cleaner to remove any accumulation on the water heater heating surfaces Do not use ...

Page 24: ...al 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 access cover 3 Remove t...

Page 25: ...eplace fuse F3 on the main control board see page 24 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 28 35 of this manual for corrective actions Unit Does Not Modulate Above 50 ...

Page 26: ...sor and S3a S3b flue sensor Please reference the wiring diagram in the Outdoor 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 8 406 194 1 08...

Page 27: ...s manual for the burner removal and inspection procedure Clean or replace the burner as necessary Low water flow through the heat exchanger Refer to Section 3 System Piping of the Armor Outdoor Water Heater Installation and Operation Manual for minimum flow rates Air in the piping system Properly purge all air from the piping system Low system water pressure Verify system pressure is a minimum of ...

Page 28: ... HEX Temp Sw Open will require a manual reset once the condition has been corrected Press the RESET button on the SMART SYSTEM display to reset Either the air pressure switch contacts are open the O temp heat exchanger switch has opened or the burner door temperature switch has opened APS Check the wiring connections to switch Wires should be connected to the common and normally closed terminals A...

Page 29: ...res should be between 8 14 inches w c Refer to Section 4 Gas Connections of the Armor Outdoor Water Heater Installation and Operation Manual for detailed information concerning the 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 correctly installed and that there are no obstructions Check for 24 V...

Page 30: ...nual for detailed information concerning the 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 replac...

Page 31: ...mp 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 on page 26 of this manual Replace sensor if necessar...

Page 32: ...h will require a manual reset once the condition has been corrected Press the RESET button on the SMART SYSTEM 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 Check for obstruction or blockage in the vent air intake pipes or at terminations Check the wiring connections at the fan and at the main control board...

Page 33: ...nsor and associated wiring Measure the resistance of the flue sensor and compare to Table 3D on page 26 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 heat exchanger has ex...

Page 34: ...int 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 water heater is pipe...

Page 35: ...nsformer 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 main contr...

Page 36: ...mbustion Levels POSSIBLE CAUSE CORRECTIVE ACTION Vent Air Intake Length or Obstruction Check for obstructions at the vent air intake terminals Gas Supply Pressure Refer to Section 4 Gas Connections of the Outdoor Armor Water Heater Installation and Operation Manual for the proper gas supply for the outdoor water heater Dirty Damaged Burner Refer to page 22 of this manual for burner removal and cle...

Page 37: ... the combustion is still not within the specified range revisit the possible causes in Table 3H on page 36 or replace the gas valve Figure 3 2 Gas Valve Adjustment Models 151 286 Model 400 Locate the throttle adjustment screw on the top of the gas valve see FIG 3 3 Using a screwdriver turn the screw 1 8 turn counterclockwise to increase CO2 levels or 1 8 turn clockwise to decrease CO2 levels After...

Page 38: ...ADJUSTMENT SCREW Figure 3 4 Gas Valve Adjustment Model 501 3 Troubleshooting Models 601 801 Locate the throttle adjustment screw on top of the gas valve see FIG 3 5 Using an Allen wrench turn the screw a 1 4 turn counterclockwise to increase CO2 levels or a 1 4 turn clockwise to decrease CO2 levels After one adjustment on the valve follow the Combustion Analysis Procedure on page 36 of this manual...

Page 39: ...Notes 39 ...

Page 40: ...s Revision A ECO C10942 initial release Revision B ECO C14411 reflects condensate trap changes R6594 on page 20 Revision C ECO C15251 reflects the addition of the burner door temperature switch R6322 on pages 6 and 28 OAW SER Rev C 06 14 ...

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