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Lochinvar 150 - 500 Installation & Operation Manual

Manual is about: Armor Water Heater

Summary of 150 - 500

  • Page 1

    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 g...

  • Page 2

    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 s...

  • Page 3

    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...

  • Page 4

    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 com...

  • Page 5

    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 15...

  • Page 6

    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.

  • Page 7

    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. ...

  • Page 8

    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, a...

  • Page 9

    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 - 2...

  • Page 10

    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 s...

  • Page 11

    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 s...

  • Page 12

    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 o...

  • Page 13

    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 ...

  • Page 14

    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 pa...

  • Page 15

    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 req...

  • Page 16

    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 support...

  • Page 17

    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 t...

  • Page 18

    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 termina...

  • Page 19

    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 b...

  • Page 20

    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...

  • Page 21

    Installation & operation manual 21 4 sidewall direct venting (continued) 4. Cut one (1) hole (5 inch diameter for #cvk3003 installations or 7 inch diameter for #cvk3007 installations) into the structure to install the termination kit. 5. Partially assemble the concentric vent termination kit. Clean ...

  • Page 22

    Installation & operation manual 22 4 sidewall direct venting sidewall termination – optional concentric vent figure 4-9 concentric vent dimensional drawing - models 150 - 199 instead of cementing the smaller pipe to the rain cap, a field-supplied stainless steel screw may be used to secure the two (...

  • Page 23

    Installation & operation manual 23 4 sidewall direct venting (continued) sidewall termination – optional concentric vent multiventing sidewall terminations when two (2) or more direct vent appliances are vented near each other, each appliance must be individually vented (see fig. 4-13). Never common...

  • Page 24

    Installation & operation manual 24 5 vertical direct venting vent/air termination – vertical follow instructions below when determining vent location to avoid possibility of severe personal injury, death or substantial property damage. Installation must comply with local requirements and with the na...

  • Page 25

    Installation & operation manual 25 5 vertical direct venting (continued) vent/air termination – vertical prepare roof penetrations 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 ...

  • Page 26

    Installation & operation manual 26 5 vertical direct venting vertical termination – optional concentric vent description and usage lochinvar offers an optional concentric combustion air and vent pipe termination kit. Both combustion air and vent pipes must attach to the termination kit. The terminat...

  • Page 27

    Installation & operation manual 27 5 vertical direct venting (continued) vertical termination – optional concentric vent figure 5-6 concentric vent roof installation ensure termination height is above the roof surface or anticipated snow level (12 inches in u.S.A. Or 18 inches in canada) as shown in...

  • Page 28

    Installation & operation manual 28 6 system piping system water piping methods observe a minimum of 1 inch clearance around all un-insulated hot water pipes when openings around the pipes are not protected by non-combustible materials. General piping information basic steps are listed below along wi...

  • Page 29

    6 system piping (continued) water heater pump applications model *pipe size armstrong flow rate (gpm) loss (ft/hd) temperature rise 150 1-1/4" e8 16 16.6 18°f 199 1-1/4" e8 21 11.8 18°f 285 2" e17 30 17.1 18°f 399 2" e24 39 21 18°f 500 2" e24 52 18.2 18°f installation & operation manual 29 table 6c ...

  • Page 30

    Installation & operation manual 30 6 system piping flow check valve (typical) ball valve (typical) expansion tank thermometer (typical) cold water supply 140° hot water supply high temperature building return drain temperature & pressure relief valve (typical) flow switch water heater circulator sto...

  • Page 31

    Installation & operation manual 31 6 system piping (continued) flow check valve (typical) expansion tank thermometer cold water supply hot water supply building return drain temperature & pressure relief valve (typical) flow switch water heater circulator storage tank water heater union (typical) ba...

  • Page 32

    Installation & operation manual 32 6 system piping flow check valve (typical) ball valve (typical) expansion tank thermometer cold water supply hot water supply building return drain (typical) temperature & pressure relief valve (typical) flow switch water heater circulator storage tank (typical) wa...

  • Page 33

    Installation & operation manual 33 6 system piping (continued) flow check valve (typical) ball valve (typical) expansion tank thermometer cold water supply hot water supply building return drain temperature & pressure relief valve water heater circulator (typical) storage tank water heater (typical)...

  • Page 34

    Installation & operation manual 34 6 system piping flow check valve (typical) ball valve (typical) expansion tank thermometer cold water supply hot water supply building return drain (typical) temperature & pressure relief valve (typical) flow switch (typical) water heater circulator (typical) stora...

  • Page 35

    Installation & operation manual 35 7 gas connections connecting gas supply piping 1. Remove the top access panel and refer to fig.’s 7-1 thru 7-3 to pipe gas to the water heater. A. Install ground joint union for servicing, when required. B. On models 150 - 399 install a manual shutoff valve in the ...

  • Page 36

    Installation & operation manual 36 7 gas connections failure to apply pipe sealing compound as detailed in this manual can result in severe personal injury, death, or substantial property damage. Armor water heaters are typically shipped ready to fire on natural gas. Check the water heater rating pl...

  • Page 37

    Installation & operation manual 37 nominal iron pipe size (inches) single unit natural gas pipe capacity chart length of pipe in straight feet for 1/2 psi 10 20 30 40 50 60 70 80 90 100 125 150 175 200 1/2 175 120 97 82 n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a 3/4 369 256 205 174 155 141 128 121 113 ...

  • Page 38

    Installation & operation manual 38 7 gas connections gas pressure the gas pressure must remain between 4 inches w.C. (natural), 8 inches w.C (lp) minimum and 14 inches w.C. (natural and lp) maximum during stand-by (static) mode and while in operating (dynamic) mode. If an in-line regulator is used, ...

  • Page 39

    Installation & operation manual 39 8 field wiring electrical shock hazard – for your safety, turn off electrical power supply before making any electrical connections to avoid possible electric shock hazard. Failure to do so can cause severe personal injury or death. Wiring must be n.E.C. Class 1. I...

  • Page 40

    Installation & operation manual 40 8 field wiring low voltage connections 1. Route all low voltage wires through the knockouts in the rear of the water heater, as shown in fig. 8-2. 2. Connect low voltage wiring to low voltage connection board as shown in fig. 8-3 on page 42 of this manual and the w...

  • Page 41

    Installation & operation manual 41 8 field wiring (continued) runtime contacts the smart system control closes a set of dry contacts whenever the burner is running. This is typically used by building management systems to verify that the water heater is responding to a call for heat. Alarm contacts ...

  • Page 42

    Installation & operation manual 42 8 field wiring figure 8-3 low voltage field wiring connections.

  • Page 43

    Installation & operation manual 43 9 condensate disposal condensate drain 1. This water heater is a high efficiency appliance that produces condensate. 2. The side of the water heater has a 1/2 inch pvc union for connection of a 1/2 inch pvc pipe (fig. 9-1). 3. Slope condensate tubing down and away ...

  • Page 44

    Installation & operation manual 44 10 start-up chlorine concentration less than 200 ppm 1. Do not fill the water heater or operate with water containing chlorine in excess of 200 ppm. 2. Filling with chlorinated fresh water should be acceptable since drinking water chlorine levels are much lower. 3....

  • Page 45

    Installation & operation manual 45 10 start-up (continued) final checks before starting the water heater read the armor water heater service manual to familiarize yourself with smart system control module operation. Read this manual, pages 46 and 47 for proper steps to start the water heater. Verify...

  • Page 46

    Installation & operation manual 46 figure 10-2 operating instructions - models 150 - 285 10 start-up.

  • Page 47

    Installation & operation manual 47 10 start-up (continued) figure 10-3 operating instructions - models 399 - 500

  • Page 48

    Installation & operation manual 48 check flame and combustion (continued) 4. Place the water heater into the active position by pressing the shutdown button on the display board (fig. 11-1, page 54) until whr:standby appears in the display window. 5. Locate the pinhole button above the “r” in the ar...

  • Page 49

    Installation & operation manual 49 10 start-up (continued) configuration of the cascade when installed in a cascade system, the individual controls must be programmed for cascade operation. This is accomplished by accessing the control parameters. Input the installer code as described in the armor w...

  • Page 50

    Installation & operation manual 50 11 operating information general how the water heater operates the armor water heater uses an advanced stainless steel heat exchanger and electronic control module that allows fully condensing operation. The blower pulls in air and pushes flue products out of the w...

  • Page 51

    Installation & operation manual 51 high limit operations when outlet temperature exceeds 200°f, high limit action occurs. The water heater shuts down until the outlet water cools down and requires manual reset of the control before operation will resume. To reset control, push the reset key on the d...

  • Page 52

    Installation & operation manual 52 11 operating information if the set point still cannot be met, the leader will continue firing more members until either the heat demand is met or all water heaters on the cascade are firing. As the heat demand decreases, the last water heater on will modulate down...

  • Page 53

    Installation & operation manual 53 11 operating information (continued) operation display 1. Upon a call for heat, the control turns on the water heater pump. Whr: standby out: 123.8f(129) 2. The control connects 120 vac to the blower. The blower does not run at this time. • the flow switch must clo...

  • Page 54

    Installation & operation manual 54 armor water heater control module figure 11-1 control panel use the control panel (fig. 11-1) to set temperatures, operating conditions, and monitor water heater operation. 11 operating information.

  • Page 55

    11 operating information (continued) status display screens by using the previous/next ( , ) arrow keys on the smart system display panel, you can navigate through the six (6) display screens. Each screen will contain two (2) viewable items. The following is a description of the individual items and...

  • Page 56

    Installation & operation manual 56 status display screens (cont’d) by using the previous/next ( , ) arrow keys on the smart system display panel, you can navigate through the six (6) display screens. Each screen will contain two (2) viewable items. The following is a description of the individual it...

  • Page 57

    Installation & operation manual 57 status display screens (cont’d) operation of the cascade the water heater designated as the leader will have two additional display screens that can be viewed. These screens will provide information regarding the operation of the cascade. Each screen will contain t...

  • Page 58

    Installation & operation manual 58 12 maintenance maintenance and annual startup table 12a service and maintenance schedules service technician (see the following pages for instructions) general: • address reported problems • inspect interior; clean and vacuum if necessary; • clean condensate trap a...

  • Page 59

    Installation & operation manual 59 12 maintenance (continued) follow the service and maintenance procedures given throughout this manual and in component literature shipped with the water heater. Failure to perform the service and maintenance could result in damage to the water heater or system. Fai...

  • Page 60

    Installation & operation manual 60 12 maintenance failure to inspect for the above conditions and have them repaired can result in severe personal injury or death. Check water system 1. Verify all system components are correctly installed and operational. 2. Check the cold fill pressure for the syst...

  • Page 61

    Installation & operation manual 61 12 maintenance (continued) 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 ...

  • Page 62

    Installation & operation manual 62 13 diagrams box depicts optional items ladder diagram lbl7097 rev f 120 vac 24 vac 120vac terminal strip 120v supply "l" x1-6 dhw pump relay blower relay x1-3 x1-1 dhw pump "l" dhw pump dhw pump "n" 1 2 3 blower junction box x1-5 x6-8 x6-3 f5 x5-7 x6-7 neutral cn4-...

  • Page 63

    Installation & operation manual 63 display x1-8 x5-5 x5-13 x5-6 x5-12 integrated control blower x1-1 x2-2 x2-1 x1-7 gas valve flame rod spark rod w/r g r r t w bk g r 1 3 2 w g box depicts optional items wiring diagram lbl7096 rev f warning disconnect power before servicing inlet sensor outlet senso...

  • Page 64

    Revision notes: revision b (aw-i&o-rev b) reflects the addition of the dungs information to the manual. Revision c (aw-i&o-rev c) reflects changes made to pages 30 and 31 (piping diagrams). Revision d (aw-i&o-rev d) reflects changes made to model 199 orifice. Revision e (aw-i&o-rev e) reflects an ad...