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  4. 151 - 801
  5. Operation Manual

Lochinvar 151 - 801 Operation Manual

Other manuals for 151 - 801: Service Manual
Manual is about: Armor Outdoor Armor Water Heater

Summary of 151 - 801

  • Page 1

    Outdoor armor water heater installation & operation 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 service manual, before installing. Perform steps in the or...

  • Page 2: Hazard Definitions

    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

    Outdoor armor water heater installation & operation manual please read before proceeding installer – read all instructions, including this manual and the outdoor armor water heater service manual, before installing. Perform steps in the order given. Have this water heater serviced/inspected by a qua...

  • Page 4

    4 the outdoor 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 combustion process. 2. Comb...

  • Page 5

    5 30 20 29 13 21 12 9 27 14 39 img00284 42 rear view - models 151 - 200 rear view - model 286 28 16 23 10 2 17 34 7 8 18 27 21 img00360 26 31 40 15 19 24 1 left side (inside unit) - model 286 the outdoor armor water heater - how it works... (continued) left side (inside unit) - models 151 - 200 mode...

  • Page 6

    6 the outdoor armor water heater - how it works... Rear view - models 601 - 801 left side (inside unit) - models 601 - 801 9 41 12 13 30 29 25 42 20 39 27 14 img00395 models 400 - 501 2 28 16 23 3 5 34 15 17 4 8 7 18 32 21 26 img00396 19 1 rear view - models 400 - 501 left side (inside unit) - model...

  • Page 7: Ratings

    Ratings notes: 1. Outdoor armor water heaters are supplied with special gas venting materials. Use only the method of installation specified in the outdoor armor installation and operation manual. 2. Standard outdoor armor water heaters are equipped to operate from sea level to 4,500 feet only with ...

  • Page 8

    1 determine water heater location 8 the outdoor armor water heater gas manifold and controls met safe lighting and other performance under tests specified in ansi z21.10.3 – latest edition. Installation must comply with: • local, state, provincial, and national codes, laws, regulations, and ordinanc...

  • Page 9

    1 determine water heater location (continued) 9 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 softening refrigerant leaks paint ...

  • Page 10: Prepare Water Heater

    10 2 prepare water heater remove water heater from wood pallet 1. After removing the outer shipping carton from the water heater, remove the installation kit. 2. Remove the front door to access the lag bolts in front of the unit (fig. 2-1). 3. To remove the water heater from the pallet (after removi...

  • Page 11: Prepare Water Heater

    2 prepare water heater (continued) model 400 1. Remove the top and front access covers from the unit (phillips screwdriver required for removal). 2. Remove the three screws securing the venturi to the blower. Note: when separating the venturi from the blower, take care not to damage the o-ring insid...

  • Page 12: Prepare Water Heater

    2 prepare water heater 12 figure 2-6 gas valve adjustment - model 501 model 501 1. Remove the top access cover from the unit (phillips screwdriver required for removal). 2. Turn the adjustment screw on the gas valve clockwise until it stops. Then turn the adjustment screw counterclockwise four and t...

  • Page 13: System Piping

    3 system piping system water piping methods observe a minimum of 1/4 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 with illustrations on the following...

  • Page 14: System Piping

    Scalding this water heater can deliver scalding temperature water at any faucet in the system. Be careful whenever using hot water to avoid scalding injury. Certain appliances such as dishwashers and automatic clothes washers may require increased temperature water. By setting the thermostat on this...

  • Page 15: System Piping

    Installation & operation manual 15 3 system piping (continued) water heater pump applications model *pipe size armstrong grundfos flow rate (gpm) loss (ft/hd) temp. Rise 151 1-1/4" e8 -- 16 16.6 18°f 200 1-1/4" e8 -- 21 11.8 18°f 286 2" e17 -- 30 17.1 18°f 400 2" e24 -- 39 21 18°f 501 2" e22 -- 53 2...

  • Page 16: System Piping

    Installation & operation manual 16 3 system piping notice please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes. Indoor tank shown for illustration purposes. The piping will not support ...

  • Page 17: System Piping

    Installation & operation manual 17 3 system piping (continued) notice please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes. Indoor tank shown for illustration purposes. The piping will ...

  • Page 18: System Piping

    18 3 system piping building return ball valve (typical) flow check valve (typical) cold water supply thermometer hot water supply union (typical) temperature & pressure relief valve (typical) storage tank (typical) drain (typical) water heater water heater circulator flow switch y-strainer (recommen...

  • Page 19: System Piping

    19 3 system piping (continued) img00362 y-strainer (recommended) ball valve (typical) union (typical) water heater (typical) water heater circulator (typical) expansion tank cold water supply flow check valve (typical) building return hot water supply thermometer thermometer & pressure relief valve ...

  • Page 20: System Piping

    20 3 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) storage tank (typical) water heater (...

  • Page 21: Gas Connections

    4 gas connections connecting gas supply piping 1. Remove the top access panel and refer to fig.’s 4-1 thru 4-4 to pipe gas to the water heater. A. Install ground joint union for servicing, when required. B. On models 151 - 400 install a manual shutoff valve in the gas supply piping outside water hea...

  • Page 22: Gas Connections

    22 4 gas connections failure to apply pipe sealing compound as detailed in this manual can result in severe personal injury, death, or substantial property damage. Outdoor armor water heaters are typically shipped ready to fire on natural gas. Check the water heater rating plate to determine which f...

  • Page 23: Gas Connections

    23 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 3/4 369 256 205 174 155 141 128 121 113 106 95 86 79 74 1 697 477 384 32...

  • Page 24: Gas Connections

    24 4 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, it must be a minimum of 10 feet...

  • Page 25: Field Wiring

    25 5 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. If original wiring as supplied wi...

  • Page 26: Field Wiring

    26 5 field wiring tank thermostat 1. Connect the tank thermostats (isolated contact only) to the tank thermostat contacts as shown in fig. 5-3. Tank sensor 1. By installing a tank sensor, the smart system control can perform the tank thermostat function. The smart system control automatically detect...

  • Page 27: Field Wiring

    27 5 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 the smart system control closes ...

  • Page 28: Field Wiring

    28 5 field wiring fl ow sw it ch t a nk sensor bui l di ng ma n a g e me n t sy s t em com no lo w w a ter c u to f f ta nk the r m o s t a t shield shield to ne x t heate r a b a b fr om previous heat e r a b im g 0 0 423 figure 5-3 low voltage field wiring connections outdoor armor water heater in...

  • Page 29: Condensate Disposal

    29 6 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. 6-1). 3. Slope condensate tubing down and away from the water heater into a dra...

  • Page 30: Start-Up

    30 7 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. Do not use the water heater to d...

  • Page 31: Start-Up

    31 7 start-up (continued) final checks before starting the water heater  read the outdoor armor water heater service manual to familiarize yourself with smart system control module operation. Read this manual, pages 32 and 33 for proper steps to start the water heater.  verify the water heater and...

  • Page 32: Start-Up

    32 for your safety read before operating warning: if you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury, or loss of life. A. This appliance does not have a pilot. It is equipped with an ignition device which automatic ally lights the...

  • Page 33: Start-Up

    33 7 start-up (continued) figure 7-3 operating instructions - models 400 - 801 outdoor armor water heater installation & operation manual.

  • Page 34: Start-Up

    34 check flame and combustion (continued) 4. Place the water heater into the active position by pressing the right select [on] key (fig. 8-1, page 40). 5. Locate the pinhole button below the reset button on the display board (fig. 8-1). Insert a thin wire (such as a paper clip) into the hole and pre...

  • Page 35: Start-Up

    35 7 start-up (continued) configuration of the cascade set clock notice the internal clock does not adjust for daylight savings time and therefore, will require a manual adjustment. The smart system control has a built-in clock that it uses for its night setback feature and for logging events. This ...

  • Page 36: Operating Information

    36 8 operating information general how the water heater operates the outdoor 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 water heater through the heat ex...

  • Page 37: Operating Information

    37 when the outlet temperature exceeds 200°f, the automatic high limit action occurs. The water heater shuts down until the outlet water temperature cools below 190°f, and a 60 second timer has expired. If the outlet temperature continues to increase, the manual reset high limit action will occur at...

  • Page 38: Operating Information

    38 8 operating information night setback operation with cascade night setback operation of the water heaters within the cascade is available. Programming of the night setback will be done through the leader water heater. Refer to the outdoor armor water heater service manual for information regardin...

  • Page 39: Operating Information

    39 8 operating information (continued) sequence of operation operation display 1. The control will turn on the water heater pump (always on except in night setback). The flow switch and/or lwco must close. 2. Air pressure switch and blocked drain switch must close. 3. The control starts a 15 second ...

  • Page 40: Operating Information

    40 outdoor armor water heater control module figure 8-1 control panel use the control panel (fig. 8-1) to set temperatures, operating conditions, and monitor water heater operation. 8 operating information the information on the bottom of the display shows the functions of the two select keys (on ei...

  • Page 41: Operating Information

    41 8 operating information (continued) status display screens section display description a (water heater status bar) standby the unit has not received a call for heat from a remote thermostat nor has it received a call for heat from a dhw thermostat. Start the unit has begun a burn cycle and is che...

  • Page 42: Operating Information

    42 8 operating information status display screens (cont’d) section display description c (operational information) tank: the temperature read by the tank sensor (if connected). Inlet temp: the temperature read at the inlet to the heat exchanger. Outlet temp: the temperature read at the outlet of the...

  • Page 43: Operating Information

    43 8 operating information (continued) status display screens (cont’d) section display description e (navigation dial function) turning the navigation dial will select the next or previous status screen. Pressing the navigation dial will show the next fault, nsb (night setback) trigger, or ramp dela...

  • Page 44: Maintenance

    44 9 maintenance maintenance and annual startup table 9a 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 and fill with fresh water • check f...

  • Page 45: Maintenance

    45 9 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. Failure to follow the directions in ...

  • Page 46: Maintenance

    46 9 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 system. Verify it is correct (must be...

  • Page 47: Maintenance

    47 9 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 a vacuum cleaner or compressed ai...

  • Page 48: Maintenance

    48 oiled bearing circulators 1. The circulator shipped with the outdoor water heater is water-lubricated. No oiling is required. 2. Check other circulators in the system. Oil any circulators requiring oil, following circulator manufacturer’s instructions. Over-oiling will damage the circulator. Chec...

  • Page 49: Diagrams

    10 diagrams figure 10-1 ladder diagram 49 outdoor armor water heater installation & operation manual box depicts optional items ladder diagram lbl20341 rev a integrated control x2-1 gas valve gas valve relay x5-7 x5-16 x5-8 x5-15 1 2 4 5 tr2 x1-7 flame rod spark rod blower connection board inlet sen...

  • Page 50: Diagrams

    50 figure 10-2 wiring diagram 10 diagrams outdoor armor water heater installation & operation manual x1-7 on/off switch 1 2 3 4 5 g r r w r t w bk y bl blower -t high limit sensor s1b operating sensor s1a inlet sensor s2 flue sensor s3a flue sensor s3b integrated control bk y gas valve @24vac spark ...

  • Page 51: Notes

    Notes installation & operation manual outdoor condensing water heater 51.

  • Page 52

    Revision notes: revision a (eco #c10942) initial release. Revision b (eco #c11235) reflects updates made to the freezing conditions warnings. Revision c (eco c12102) reflects the addition of condensate kit option information for areas that may reach below 32°f as well as a warning not to install oa ...