Lochinvar 1.5 manual

Service Manual Models: 1.0, 1.3, and 1.5 This manual must only be used by a qualified heating installer / service technician. Read all instructions, including this manual and the Armor X2 Installation and Operation Manual, before installing. Perform steps in the order given. Failure to comply could result in severe personal injury, death, or substa[...]

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 [...]

3 Service Manual Installer – Read all instructions, including this manual and the Armor X2 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 perso[...]

What is in this manual? 4 Service Manual Service The Armor X2 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 m[...]

1 Service The Armor X2 display 5 Service Manual[...]

FLOW SW ITC H SEQUENCE R / BUILDING MANA GEMENT SYSTEM LOW VOLTAGE CONNECTION BOA RD PRIMARY /SECONDARY INLET TEMPERATURE SENSOR PRIMARY/ SECONDARY FLUE GAS SENSOR PRIMARY /SECONDARY HIGH LIMIT SENSOR PRIMARY /SECONDARY FLAME SENSOR BLOCKED DRAIN SWITCH TOUCH PANEL INTERFACE PC INTERFACE SECONDARY SMART CONTROL MODULE PRIMARY SMART CONTROL MODULE H[...]

LOW V OL T A GE CONNECTION BOA RD PRIM AR Y CONTROL MO DULE ALARM BELL RUN TIME CONT ACT S SEQUENCE R / BUILDING MANAGEM ENT SYSTEM HEA T EXCHANGER 1 / HEA T EXCHANGER 2 HW PUMP IGNITOR BLOW ER GAS V AL VE PC INTERF ACE SE CONDAR Y SMART T OUCH CONTROL MO DUL E TOUCH P ANEL INTERF ACE TOUCH DISPLA Y SMAR T TOUCH Control outputs 1 Service (continued[...]

General Operation How the water heater operates The Armor X2 uses two (2) advanced stainless steel heat exchangers and two (2) electronic control modules that allow fully condensing operation. The blowers pull in gas and air and push flue products out of the water heater through the heat exchangers and flue piping. The control modules regulate blow[...]

1 Service (continued) Sequence of operation Table 1A Sequence of operation Note: This unit is equipped with two (2) independent, but synchronized combustion systems. One of the heat exchanger combustion systems will fire first. If the demand cannot be met by one (1) combustion system the same sequence of operation will be followed to bring the seco[...]

Parameter table Table 1B This table lists the parameters and where to access them MENU DESCRIPTION SEE PAGE USER ACCESS INSTALLER ACCESS DISPLAY MODIFY DISPLAY MODIFY Service/Setup 17 Yes Yes Yes Yes Night Setback 17 Yes Yes Yes Yes Set points 17 Yes Yes Yes Yes Cascade 17 Yes Yes Yes Yes BMS 17 Yes Yes Yes Yes SETUP Demand Conf 18 Yes No Yes No Se[...]

Date and time 21 Yes Yes Yes Yes On Timer and Off Timer 21 No No Yes Yes NIGHT Table 1B (continued from previous page) This table lists the parameters and where to access them Casc Address 22 Yes Yes Yes Yes Casc off df 22 No No Yes Yes Casc off/on df 22 No No Yes Yes Max Outl temp 22 No No Yes Yes CASCADE 1 Service (continued) SETBACK BMS Type 23 [...]

Viewable and changeable control parameters Status Screen: When the ON/OFF switch is turned to the ON position, the first screen visible on the LCD display will be the Status Screen. This screen displays the current status of the Armor X2 water heater. The following items can be viewed or interacted with on the Status Screen: On/Off button - Pressin[...]

Configuration - This line shows the current configuration of the two control modules inside the unit. Outlet Water Temperature - This is a calculated temperature based on the readings of the outlet temperatures of the two (2) heat exchangers. Inlet Water Temperature - This is a calculated temperature based on the inlet temperature readings from the[...]

1 Service Details Screen: The Details Screen is accessed by pressing the DETAIL button on the Status Screen. This screen shows the status of the various safeties, inputs and outputs to each control module. Selection of the control module to be viewed is accomplished by pressing the SELECT button. The control module being displayed is shown in the m[...]

15 1 Service (continued) A blank message box is located on the Details Screen. This box will display various messages detailing the status of the control module. If a message is present in this box, the DETAILS button on the Status Screen will contain a yellow triangle with an exclamation mark (!) inside. Displayed items are as follows: • Delta T[...]

16 Main Screen: 1 Service The Main Screen allows navigation to eight (8) additional screens which are used to set temperatures, operating conditions, and monitor water heater operation. These screens are as follows: • Setup - Allows access to five (5) other screens for the adjustment of the control parameters. • Cascade - Shows the status of mu[...]

Setup Screen: The Setup Screen allows access to five (5) other screens for adjusting control parameters. These screens are as follows: • Service / Setup - Allows access to change service notification parameters, LCD backlight parameters, and temperature units. • Setpoints - Allows access to change the HW set point and ON/OFF differentials. • [...]

Service/Setup Parameters Screen: 1 Service The Service / Setup Screen allows access to 10 parameters. Those parameters are as follows: • Demand Configuration - Sets the configuration of the control modules inside the water heater. The configuration selections are: Demand Configuration 1: Cascade Set Point Thermostat based - the control modulates [...]

1 Service (continued) • Maximum Service Time - Service Mode allows the installer to control the fan speed of the individual control modules for the purposes of combustion analysis. Service Mode will override all other heat demands, however, all safeties will remain intact. Maximum service time sets the length of time the water heater will stay in[...]

1 Service Set Point Parameters Screen: The Set Point Screen allows access to 6 parameters. Those parameters are as follows: • Hot Water Tank Set Point - The hot water tank set point sets the target temperature of the water in the tank. This parameter can be changed by the user or the installer. The temperature range of this parameter is 60° to 1[...]

1 Service (continued) 21 Night Setback Parameters Screen: The Night Setback Screen allows access to 15 parameters. Those parameters are as follows: • Date and Time - The control uses an internal clock for the night setback feature and for logging of events. For these features to work correctly, the clock must be set when the heater is first insta[...]

1 Service 22 Cascade Parameters Screen: Cascade Operation When multiple water heaters are installed, they can be wired together in a cascade sequence. A maximum of eight (8) heaters can be controlled from a single control. In this application one heater would be designated as the Leader and all others would be designated as Members. The designated [...]

1 Service (continued) 23 0 - 10Vdc BMS Parameters Screen: 0-10Vdc Operation When the Demand Configuration parameter (see page 18) is set to either Cascade BMS Thermostat Based, Cascade BMS Voltage Based, Cascade Modbus BMS Thermostat Based, or Cascade Modbus BMS Voltage Based; a 0 - 10Vdc signal can be supplied to the terminal strip connection or t[...]

1 Service 24 • BMS Modulation at Minimum Voltage - Determines the modulation rate of the unit or cascade when the BMS input voltage is at or below the setting of the BMS Voltage at Minimum Modulation parameter. This parameter is only active when the BMS Type is set to modulation rate. This parameter can only be changed by the installer. The range[...]

1 Service (continued) 25 Cascade Screen: The Cascade Screen provides the status of the cascade system. Items that can be viewed on the Cascade Screen are as follows: Water Heater Power Level Indicators - For each water heater present in the cascade a power level indicator will be present above its corresponding number. The level will rise and fall [...]

1 Service 26 1 80 34 55 On Modbus Address - This is the address of a specific Armor X2 water heater. This address is set by dip switches on the Modbus communication board. The value displayed here should be the same as the value of the dip switches. The Building Automation System should use this address to communicate with the water heater. Boiler [...]

1 Service (continued) Temps Screen: The Temps Screen displays the various temperatures as measured by sensors connected to each control module. Items that can be viewed on the Temps Screen are as follows: • Inlet 1-2 - This is the water temperature as measured by the sensor located in the inlet of each heat exchanger. • Outlet 1-2 - This is the[...]

1 Service Burners Screen: This screen provides the status of the combustion air blowers and flame signals. Items that can be viewed on the Burners Screen are as follows: • Blower Power Level Indicator - Two (2) blowers are depicted on the display. The top blower corresponds with Heat Exchanger 1 or Top heat exchanger. The lower blower corresponds[...]

Graph Select Screen: The Graphs Screen consists of two (2) different screens. The first screen is the Parameter Selection Screen. By pressing the box beside the desired item, a check will appear in the selected box and the control will graph the status of that item. A maximum of five (5) items can be graphed at one time. The second screen is access[...]

History Screen: 1 Service The History Screen shows the status of various counters and faults for each control module. Selection of the control module to be viewed is accomplished by pressing the SELECT button. The control module being displayed is shown in the module box. Items that can be viewed on the History Screen are as follows: • Successful[...]

1 Service (continued) Service Mode Screen: The Service Mode Screen allows the individual control modules to override all other heat demands and operate at a full fire condition for the purpose of combustion analysis. Selection of the control module to be placed into Service Mode is accomplished by pressing the SELECT button. The control module bein[...]

2 Maintenance Maintenance and annual startup Table 2A 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 for leaks (water, gas, flue, condensate) • V[...]

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 this manual and component literature could result in severe personal injury, de[...]

Flue vent system and air piping 1. Visually inspect the entire flue gas venting system and air piping for blockage, deterioration or leakage. Repair any joints that show signs of leakage. Verify that air inlet pipe is connected and properly sealed. 2. Verify that water heater vent discharge and air intake are clean and free of obstructions. Failure[...]

Inspect ignition and flame sense electrodes 1. Remove the ignition and flame sense electrodes from the water heater heat exchanger access cover. 2. Remove any deposits accumulated on the ignition/flame sense electrode using sandpaper. If the electrodes cannot be cleaned satisfactorily, replace with new ones. 3. Replace ignition/flame sense electrod[...]

2 Maintenance The water heater contains ceramic fiber materials. Use care when handling these materials per instructions on page 3 of this manual. Failure to comply could result in severe personal injury.  WARNING Cleaning water heater heat exchanger For recommended materials; including brush, appropriate extension(s), refractory cover, and deta[...]

3 Troubleshooting 37 Alarm Screen: If a fault occurs which requires a Manual Reset, the unit will go into a lockout condition and the Alarm Screen will be activated. The screen will switch between a black or red background every 5 seconds with the text “Alarm Unit Needs Servicing” shown on the display. A message box shows the alarm status of th[...]

3 Troubleshooting 38 Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Always disconnect power to the water heater before servicing. Failure to comply could result in severe personal injury, death, or substantial property damage. Never jumper (bypass) any device except for mome[...]

3 Troubleshooting (continued) 39 Table 3A Troubleshooting Chart - No Display FAULT CAUSE CORRECTIVE ACTION No Display - No 120 VAC supplied to unit. • Check external line switch, fuse, or breaker. • Check position of ON/OFF switch. Turn switch to the ON position. • Check 120 VAC through the ON/OFF switch. • Check wiring harness connection b[...]

3 Troubleshooting 40 Table 3B - Inlet/Outlet and Tank Sensor Resistance vs. Temperature Temperature Resistance Temperature Resistance 50 18,780 158 1,990 68 12,263 176 1,458 86 8,194 194 1,084 104 5,592 212 817 122 3,893 -- -- 140 2,760 -- -- Table 3C - Flue Temperature Sensor Resistance vs. Temperature Temperature Resistance Temperature Resistance[...]

3 Troubleshooting (continued) 41 Table 3D Troubleshooting Chart - Noisy System FAULT CAUSE CORRECTIVE ACTION Noisy Operation - Supply gas problem. Natural gas pressures should be between 4 inches w.c. (1.0 kPa) and 14 inches w.c. (3.5 kPa). LP gas pressures should be between 8 inches w.c. (2.0 kPa) and 14 inches w.c. (3.2 kPa). • Refer to Section[...]

3 Troubleshooting Table 3E Troubleshooting Chart - Fault Messages Displayed on Water Heater Interface FAULT DESCRIPTION CORRECTIVE ACTION Flow Switch/ LWCO (will require a manual reset once condition has been corrected. Press the RESET button on the display to reset.) Either the flow switch or the optional AUX switch is not making. • Check water [...]

3 Troubleshooting (continued) 43 Table 3E (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Water Heater Interface FAULT DESCRIPTION CORRECTIVE ACTION Burner Did Not Light (cont’d) (will require a manual reset once the condition has been corrected. Press the RESET button on the display to reset.) The unit has fail[...]

3 Troubleshooting 44 Table 3E (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Water Heater Interface FAULT DESCRIPTION CORRECTIVE ACTION Flame Lost While Running (cont’d) (will require a manual reset once the condition has been corrected. Press the RESET button on the display to reset.) The unit was running and [...]

Table 3E (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Water Heater Interface FAULT DESCRIPTION CORRECTIVE ACTION Automatic Reset High Limit / HEX- Temp SW (will require a manual reset once the condition has been corrected. Press the RESET button on the display to reset.) Either the auto-reset high limit, or the[...]

3 Troubleshooting Table 3E (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Water Heater Interface FAULT DESCRIPTION CORRECTIVE ACTION Blower RPM’s Too High (will require a manual reset once the condition has been corrected. Press the RESET button on the display to reset.) The actual fan rpm is 30% higher than wh[...]

Table 3E (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Water Heater Interface FAULT DESCRIPTION CORRECTIVE ACTION Air Flow Too Low (will require a manual reset once the condition has been corrected. Press the RESET button on the display to reset.) Air pressure switch contacts are open. • Check the wiring conne[...]

3 Troubleshooting 48 Table 3E (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Water Heater Interface FAULT DESCRIPTION CORRECTIVE ACTION Internal Fault The main control board has detected an internal fault. • Replace the main control board. Writing to Memos The main control board has detected an internal fault. [...]

3 Troubleshooting (continued) Table 3G Troubleshooting Chart - Combustion Levels POSSIBLE CAUSE CORRECTIVE ACTION Vent/Air Intake Length or Obstruction • Refer to Section 3 - General Venting of the Armor X2 Installation and Operation Manual for the proper venting and air intake methods for the Armor X2 water heater. • Check for obstructions at [...]

50 3 Troubleshooting Gas valve adjustment procedure If adjustment of the gas valve is deemed necessary, use the following procedures: ( Note: The procedures below are model specific.) THROTTLE A DJUSTM E NT SCREW Figure 3-2 Gas Valve Adjustment: Model 1.0 Model 1.0 Locate the throttle adjustment screw on top of the gas valve, see FIG. 3-2. Using a [...]

Notes 51[...]

Revision Notes: Revision A (ECO #C09645) initial release. AWX2-SER Rev A 1/12[...]