Lochinvar 402 Service Manual
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Lochinvar 402 Service Manual

Copper-fin ii/iie boiler and water heater
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CFX-CHX-SER Rev C
Copper-fin II/IIE
Boiler and Water
Heater
Service Manual
Models: 402 - 2072
This manual must only be used
WARNING
by a qualified heating installer
/ service technician. Read all
instructions,
including
this
manual and the 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.
Save this manual for future reference.

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  • Page 1 CFX-CHX-SER Rev C Copper-fin II/IIE Boiler and Water Heater Service Manual Models: 402 - 2072 This manual must only be used WARNING by a qualified heating installer / service technician. Read all instructions, including this manual and the Installation and Operation Manual, before installing.

  • Page 2: Table Of Contents

    Contents 2. MAINTENANCE CONTENTS ................ 2 Maintenance and Annual Startup ........ 25-32 Hazard Definitions .............. 2 3. TROUBLESHOOTING PLEASE READ BEFORE PROCEEDING ......3 Before Troubleshooting ............ 33 Handling Ceramic Fiber Materials ........3 Check Control Module Fuses .......... 33 When servicing appliance ..........

  • Page 3: Please Read Before Proceeding

    Copper-fin II/IIE Boiler and Water Heater Service Manual Please read before proceeding Installer – Read all instructions, including When servicing appliance – WARNING this manual and the Installation and • To avoid electric shock, disconnect electrical supply Operation Manual, before installing. before performing maintenance.

  • Page 4: What Is In This Manual

    Copper-fin II/IIE Boiler and Water Heater Service Manual What is in this manual? Maintenance Service The Copper-fin display • Service and maintenance schedules • Address reported problems • Display panel readout, buttons and their functions • Inspect appliance area and appliance interior Control module inputs •...

  • Page 5: Service

    Copper-fin II/IIE Boiler and Water Heater Service Manual Service The Copper-fin display • Hold 5 seconds to enter code Input Mode (Menu Mode) • 2-Line / 16 character LCD display • Press to turn heater off or back on • Press to move up one level •...

  • Page 6: Control Inputs

    Copper-fin II/IIE Boiler and Water Heater Service Manual Service Control inputs OUTDOOR SENSOR (OPTIONAL) SYSTEM SUPPLY/ ENABLE SENSOR (OPTIONAL) SENSOR SYSTEM RETURN SENSOR CONNECTION BOARD (OPTIONAL ON BOILER) (BOILER AND VOLTAGE POOL HEATER CONNECTION ONLY) BOARD SYSTEM PUMP SPEED (OPTIONAL) CASCADE DHW THERMOSTAT (OPTIONAL)

  • Page 7: Control Outputs

    Copper-fin II/IIE Boiler and Water Heater Service Manual Service (continued) Control outputs MODBUS VOLTAGE MODBUS CONNECTION BOARD 0-10V BOARD (OPTIONAL) FIRING RATE CASCADE THREE WAY VALVE (OPTIONAL ON BOILER) LOUVER RELAY BUILDING MANAGEMENT SYSTEM RUN TIME CONTACTS ALARM CONTACTS SMART SYSTEM ALARM CONTROL...

  • Page 8: General Operation

    Copper-fin II/IIE Boiler and Water Heater Service Manual Service General Operation How the appliance operates Access modes The Copper-fin uses a finned copper tube heat exchanger to User transfer heat from the flue products to the water. An electronic The user can adjust space heating and/or tank setpoints using control module monitors various inputs to initiate a call for the UP and DOWN buttons at any time during normal...
  • Page 9 Copper-fin II/IIE Boiler and Water Heater Service Manual Service (continued) Sequence of operation Table 1A_Sequence of Operation - Space Heating and DHW OPERATION DISPLAY HTR: Standby 1. The manual reset high limit must be closed before any action will take place. OUT: 123.8F(129) 2.
  • Page 10 Copper-fin II/IIE Boiler and Water Heater Service Manual Service Sequence of operation Table 1A_(continued from previous page) Sequence of Operation - Space Heating and DHW OPERATION DISPLAY 9. If the DHW thermostat remains on for more than 30 minutes, and the space heating call for heat is also on, then the control will turn on the boiler pump, turn off the DHW pump HTR: RUN STG 12 after 2 seconds, and resume firing based on the space...

  • Page 11: Display Panel Menu Access

    Copper-fin II/IIE Boiler and Water Heater Service Manual Service (continued) Display panel menu access Table 1B_Use this procedure to access menus from the display panel Note: Not all menu listings shown above are available on water heaters.

  • Page 12: Display Panel Parameter Access

    Copper-fin II/IIE Boiler and Water Heater Service Manual Service Display panel parameter access Table 1C_This is a typical example of accessing a parameter, shown for parameter K2, SH pump delay Cascade...

  • Page 13: Parameter Table A - Boiler Operation

    Copper-fin II/IIE Boiler and Water Heater Service Manual Service (continued) Parameter table A - Boiler Operation Table 1D_This table lists SMART SYSTEM control module parameters and where to access them for boiler operation ONLY User Access Installer Access Menu Description Item Page Display Modify...

  • Page 14: Parameter Table A - Boiler Operation

    Copper-fin II/IIE Boiler and Water Heater Service Manual Service Parameter table A - Boiler Operation (continued) Table 1D_(continued from previous page) This table lists SMART SYSTEM control module parameters and where to access them for boiler operation ONLY User Access Installer Access Menu Description...

  • Page 15: Parameter Table B - Water Heater Operation

    Copper-fin II/IIE Boiler and Water Heater Service Manual Service (continued) Parameter table B - Water Heater Operation Table 1E_This table lists SMART SYSTEM control module parameters and where to access them for water heater operation ONLY User Access Installer Access Menu Description Item...

  • Page 16: Parameter Table B - Water Heater Operation

    Copper-fin II/IIE Boiler and Water Heater Service Manual Service Parameter table B - Water Heater Operation (continued) Table 1E_(continued from previous page) This table lists SMART SYSTEM control module parameters and where to access them for water heater operation ONLY User Access Installer Access Menu...

  • Page 17: Viewable And Changeable Control Parameters

    Copper-fin II/IIE Boiler and Water Heater Service Manual Service (continued) Viewable and changeable control parameters Before changing parameters, note the Example: Monday ON: 22:30, Tuesday OFF: 6:45. If you wish CAUTION settings so that the unit can be returned to to skip a day and have no night setback, set the on and off times its original operating parameters.

  • Page 18: Data Logging

    Copper-fin II/IIE Boiler and Water Heater Service Manual Service SH Maximum setpoint (boiler only) Ignition attempts The SH maximum setpoint sets the maximum water temperature The burner cycles parameter shows the total number of times setpoint that can be used for space heating. The user or installer the unit has attempted to fire.
  • Page 19 Copper-fin II/IIE Boiler and Water Heater Service Manual Service (continued) Freeze protection pump on DHW/SH switching time (boiler only) In order to prevent the water in the heater from freezing, the The time that the SMART SYSTEM control services a DHW SMART SYSTEM control turns on the boiler pump whenever demand before returning to the SH demand is set by this the inlet temperature goes below the minimum temperature.
  • Page 20 Copper-fin II/IIE Boiler and Water Heater Service Manual Service Figure 1-1_Outdoor Air Reset Curve Outdoor air reset (boiler only) Maximum SH setpoint When the outdoor temperature drops to its minimum Outdoor air reset operation setting (F1) the water temperature setpoint will be at this When the outdoor air sensor is installed, the control will value, if the SH setpoint is set higher (FIG.
  • Page 21 Copper-fin II/IIE Boiler and Water Heater Service Manual Service (continued) Outdoor air shutdown differential Minimum On/Off delay Stages 1, 3 The outdoor air shutdown differential parameter is the number Whenever Stage 1 or Stage 3 (if used) starts or stops, a timer is of degrees below parameter F5 the outdoor air temperature started.
  • Page 22 Copper-fin II/IIE Boiler and Water Heater Service Manual Service Control modes BMS input (active / inactive) The setpoint or the firing rate may be controlled by a SH controlling sensor (boiler only) 0 - 10V signal from a BMS. This signal can be a 0 - 10V The SH controlling sensor parameter selects the sensor the voltage connected to the BMS input, or a 0 - 10V value control will use to regulate the boiler firing rate.
  • Page 23 Copper-fin II/IIE Boiler and Water Heater Service Manual Service (continued) Cascade Building Management System (BMS) BMS type Boiler address When the unit or cascade is controlled by the 0-10V BMS input, The boiler designated as the Leader needs to be programmed the voltage signal can control either the firing rate (power) or with address 0.

  • Page 24: Circulation Pumps

    Copper-fin II/IIE Boiler and Water Heater Service Manual Service Service Notification Maximum setpoint This setting determines the setpoint used by the unit or cascade Service interval time (months) when the BMS voltage is at or above the Voltage at Maximum When the boiler control determines that a scheduled service is setting.

  • Page 25: Maintenance

    Copper-fin II/IIE Boiler and Water Heater Service Manual Maintenance Maintenance and annual startup Table 2A_Service and Maintenance Schedules Service technician Owner maintenance (see the following pages for instructions) (see the User’s Information Manual for instructions) • Check appliance area General: •...

  • Page 26: Address Reported Problems

    Copper-fin II/IIE Boiler and Water Heater Service Manual Maintenance Follow the service and maintenance procedures given throughout this manual and in component literature WARNING shipped with the appliance. Failure to perform the service and maintenance could result in damage to the appliance or system.

  • Page 27: Check Relief Valve

    Copper-fin II/IIE Boiler and Water Heater Service Manual Maintenance (continued) Check relief valve Inspect/replace hot surface igniter This unit uses a proven hot surface ignition module and a 1. Inspect the relief valve and lift the lever to verify flow. hot surface igniter.

  • Page 28: Check Control Settings

    Copper-fin II/IIE Boiler and Water Heater Service Manual Maintenance Check all wiring Check flue gas passageways 1. Inspect all wiring, making sure wires are in good condition Any sign of soot around the refractory, at the burners, or in the and securely attached.
  • Page 29 Copper-fin II/IIE Boiler and Water Heater Service Manual Maintenance (continued) Checking combustion air pressure Access to the burners will require the following steps: Turn off main electrical power to the appliance. The combustion air fans are factory pre-set and should not require adjustment in most cases.
  • Page 30 Copper-fin II/IIE Boiler and Water Heater Service Manual Maintenance Adjusting combustion air pressure Checking manifold gas pressure The following is a recommended method for setting the Turn the appliance power switch to the “OFF” position. combustion air pressure. The following pressure settings are Remove the upper outer access panels.
  • Page 31 (UNDER CAP PRESSURE SCREW) INLET OUTLET TO BARBED MANOMETER VALVE FITTING CONTROL KNOB TABLE 2B Net Manifold Pressure Regulator Pressure Less Front Chamber Pressure MODEL Nat. Gas 402 - 752 1.8'' w.c. 4.6" w.c. 992 - 2072 1.2'' w.c. 4.6" w.c.

  • Page 32: Review With Owner

    Copper-fin II/IIE Boiler and Water Heater Service Manual Maintenance Inspect and clean the heat exchanger Turn off the main electrical power to the appliance. Turn off the main manual gas shutoff to the appliance. Remove the lower outer fron access door. Disconnect the manifold(s) from the gas train using the union(s) just below each gas valve.

  • Page 33: Troubleshooting

    Copper-fin II/IIE Boiler and Water Heater Service Manual Troubleshooting Check control module fuses Label all wires prior to disconnection when WARNING servicing controls. Wiring errors can cause ALWAYS check control module fuses before improper and dangerous operation. Always NOTICE replacing control module or any major disconnect power to the appliance before components (blower, etc.).

  • Page 34: Table 3A - Troubleshooting Chart - No Display

    Copper-fin II/IIE Boiler and Water Heater Service Manual Troubleshooting Table 3A Troubleshooting Chart - No Display FAULT CAUSE CORRECTIVE ACTION • Check external line switch, fuse, or breaker. • Check position of ON/OFF switch. Turn switch to the - No 120 VAC supplied to unit. ON position.

  • Page 35: Checking Temperature Sensors

    Copper-fin II/IIE Boiler and Water Heater Service Manual Troubleshooting (continued) Checking temperature sensors The appliance temperature sensors (inlet water, outlet water, system water, tank water, flue, and outdoor air) are all resistance type devices. The following tables show the correct values for the sensors at various temperatures. Use an ohmmeter to read the resistance of the sensor at a known temperature.

  • Page 36: Table 3D - Troubleshooting Chart - Noisy System

    Copper-fin II/IIE Boiler and Water Heater Service Manual Troubleshooting Table 3D Troubleshooting Chart - Noisy System FAULT CAUSE CORRECTIVE ACTION - Gas supply problem. • Refer to the Gas Connections Section of the Installation Operation Manual detailed information concerning the gas supply. - Gas/air mixture problem.

  • Page 37: Table 3E - Troubleshooting Chart - Fault Messages

    Copper-fin II/IIE Boiler and Water Heater Service Manual Troubleshooting (continued) Table 3E Troubleshooting Chart - Fault Messages Displayed on Operator Interface FAULT DESCRIPTION CORRECTIVE ACTION - Either the optional manual reset low gas • Reset the pressure switches. pressure switch or the optional manual reset high gas pressure switch tripped.

  • Page 38: Corrective Action

    Copper-fin II/IIE Boiler and Water Heater Service Manual Troubleshooting Table 3E (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Operator Interface FAULT DESCRIPTION CORRECTIVE ACTION The unit has failed to prove burner flame • Inspect igniter and associated wiring for damage and upon ignition.
  • Page 39 Copper-fin II/IIE Boiler and Water Heater Service Manual Troubleshooting (continued) Table 3E (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Operator Interface FAULT DESCRIPTION CORRECTIVE ACTION The unit was running and lost the flame signal. • Inspect igniter and associated wiring for damage and connection.
  • Page 40 Copper-fin II/IIE Boiler and Water Heater Service Manual Troubleshooting Table 3E (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Operator Interface FAULT DESCRIPTION CORRECTIVE ACTION The outlet water temperature has exceeded • Verify setting of adjustable high limit. the setting of the adjustable high limit.
  • Page 41 RESET button on the SMART SYSTEM display to reset.) • Check the tank temperature. Sensors equipped with an internal limit (such as the Lochinvar Squire ® Indirect Tank), the Tank Open • Repair or replace the sensor wiring if damaged.
  • Page 42 Copper-fin II/IIE Boiler and Water Heater Service Manual Troubleshooting Table 3E (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Operator Interface FAULT DESCRIPTION CORRECTIVE ACTION The temperature rise across the heat • Verify that the system is full of water and that all air exchanger has exceeded the set parameters has been properly purged from the system.
  • Page 43 Copper-fin II/IIE Boiler and Water Heater Service Manual Troubleshooting (continued) Table 3E (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Operator Interface FAULT DESCRIPTION CORRECTIVE ACTION • Establish a heating load to remove heat from the system. •...

  • Page 44: Revision Notes

    Revision Notes: Revision A (ECO #C11226) initial release to reflect the new manual name and removal of the pool heater information. Revision B (ECO C11706) reflects the update of information with the “SH Controlling Sensor (boiler only)” section on page 22. Revision C (ECO C13992) reflects edits made to the descriptions on page 22.

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2072

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