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C(F,H,P)X-SER Rev A
Copper-fin II/IIE
Boiler, Water Heater
and Pool Heater
Service Manual
Models: 402 - 2072
(Boiler & Water Heater)
Models: 502 - 2072
(Pool Heater)
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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Table of Contents
Troubleshooting
Related Manuals for Lochinvar SMART SYSTEM 402 - 2072
Summary of Contents for Lochinvar SMART SYSTEM 402 - 2072
- Page 1 C(F,H,P)X-SER Rev A Copper-fin II/IIE Boiler, Water Heater and Pool Heater Service Manual Models: 402 - 2072 (Boiler & Water Heater) Models: 502 - 2072 (Pool Heater) This manual must only be used WARNING by a qualified heating installer / service technician. Read all...
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Page 2: Table Of Contents
CONTENTS ... 2 Hazard Definitions ... 2 PLEASE READ BEFORE PROCEEDING ... 3 Handling Ceramic Fiber Materials ... 3 When servicing appliance ... 3 Appliance operation ... 3 Appliance water ... 3 WHAT IS IN THIS MANUAL ... 4 1. SERVICE The Copper-fin Display ... -
Page 3: Please Read Before Proceeding
Avoid breathing dust and contact with skin and eyes. Copper-fin II/IIE Boiler, Water Heater and Pool When servicing appliance – • To avoid electric shock, disconnect electrical supply before performing maintenance. • To avoid severe burns, allow appliance to cool before performing maintenance. -
Page 4: What Is In This Manual
• I: Cascade • J: Building Management System (BMS) • K: Pumps • L: Service Notification Copper-fin II/IIE Boiler, Water Heater and Pool Maintenance • Service and maintenance schedules • Address reported problems • Inspect appliance area and appliance interior •... -
Page 5: Service
• Press to change displayed data values in Menu Mode • Press to navigate through menu listing in Menu Mode Copper-fin II/IIE Boiler, Water Heater and Pool DISPLAY SCREEN • Press to toggle display during normal operation to show outlet and return temperatures, fan speed, flame signal, etc. -
Page 6: Control Inputs
LOW WATER CUTOFF (OPTIONAL) GAS PRESSURE SWITCH (OPTIONAL) MANUAL RESET HIGH LIMIT (OPTIONAL) AIR PRESSURE SWITCH FLOW SWITCH DISPLAY PANEL PC INTERFACE (OPTIONAL) Copper-fin II/IIE Boiler, Water Heater and Pool VOLTAGE CONNECTION BOARD MODBUS BOARD (OPTIONAL) Service Manual SENSOR CONNECTION BOARD... -
Page 7: Control Outputs
Control outputs MODBUS BOARD (OPTIONAL) SMART SYSTEM CONTROL BOARD INDICATES CONNECTIONS MADE TO THE LINE VOLTAGE TERMINAL STRIP LOCATED IN THE CONTROL PANEL AREA Copper-fin II/IIE Boiler, Water Heater and Pool VOLTAGE CONNECTION BOARD Service Manual MODBUS 0-10V POWER CASCADE... -
Page 8: General Operation
DHW operation. The combined operation sequence is for a typical application, programmed to provide DHW priority. Copper-fin II/IIE Boiler, Water Heater and Pool Access modes User The user can adjust space heating set point using the UP and DOWN buttons at any time during normal operation. - Page 9 DHW tank instead. The control will then fire the stages to maintain the outlet temperature to the DHW boiler set point. Copper-fin II/IIE Boiler, Water Heater and Pool HTR: Standby OUT: 123.8F(129) HTR: Standby OUT: 123.8F(129)
- Page 10 11. Boiler pump off, system pump continues its delay if longer. 12. System pump off. Copper-fin II/IIE Boiler, Water Heater and Pool HTR: RUN STG 12 OUT: 123.0F(129) HTR: POSTPURGE OUT: 127.4F(129) HTR: Standby OUT: 124.7F(129)
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Page 11: Display Panel Menu Access
Copper-fin II/IIE Boiler, Water Heater and Pool 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, Water Heater and Pool 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
Setpoint at Low Outdoor Temperature Setpoint at High Outdoor Temperature Outdoor Shutdown Setpoint Outdoor Shutdown Differential Shfit Reset Curve Boost Temperature Boost Time Copper-fin II/IIE Boiler, Water Heater and Pool Description Page Service Manual User Access Installer Access Display Modify... - Page 14 Boiler Pump Delay DHW Pump Delay System Pump Mode Service Calendar Time (months) Service Run Time (hours) Service Cycles Reset Service Reminder Personality Plug Copper-fin II/IIE Boiler, Water Heater and Pool Description Page Service Manual User Access Installer Access Display Modify...
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Page 15: Viewable And Changeable Control Parameters
A6. Each day of the week (Monday through Sunday) will have an on and off time. Copper-fin II/IIE Boiler, Water Heater and Pool Example: Monday ON: 22:30, Tuesday OFF: 6:45. If you wish to skip a day and have no night setback, set the on and off times to the same time, and prior to 12:00 p.m. - Page 16 DHW firing mode. This parameter can be viewed by the user and the installer by accessing parameter C2. Copper-fin II/IIE Boiler, Water Heater and Pool C3: Burner cycles The burner cycles parameter shows the total number of times the unit has attempted to fire.
- Page 17 60°F (16°C) to the value of parameter E3 to 190°F (88°C). The default temperature is 190°F (88°C). Copper-fin II/IIE Boiler, Water Heater and Pool E5: SH/DHW switching time (boiler only) When a SH call for heat and a DHW call for heat are present at the same time, the SMART SYSTEM control can switch back and forth between the two calls.
- Page 18 F2. The temperature range of this parameter is -22°F (-30°C) to 86°F (30°C). The default value is 70°F (21°C). Copper-fin II/IIE Boiler, Water Heater and Pool F3: Maximum SH set point When the outdoor temperature drops to its minimum setting (F1) the water temperature set point will be at this value, if the SH set point is set higher (FIG.
- Page 19 The control will use the water temperature at the time it shut off as the starting point. Copper-fin II/IIE Boiler, Water Heater and Pool If the temperature drops below the temperature parameter the control will abort anti-cycling and allow the unit to fire.
- Page 20 Outlet Sensor. H2: Enable input (active / inactive) The boiler or water heater can receive a call for heat in two different ways. First, an external contact (like a tank thermostat) or sensor (like a tank sensor) can generate a call for heat.
- Page 21 I4. The temperature range for this parameter is 0°F (0°C) - 54°F (30°C).The default value is 19.8°F (11°C). Copper-fin II/IIE Boiler, Water Heater and Pool J: Building Management System (BMS) J1: BMS type When the unit or cascade is controlled by the 0-10V BMS input, the voltage signal can control either the firing rate (power) or the set point.
- Page 22 K3: DHW pump delay The DHW pump delay parameter sets the length of time the DHW pump (boiler), or unit pump (water heater) will run after a DHW demand has been satisfied. This parameter is adjustable by the installer by accessing parameter K3. The time range for this parameter is 1 minute to 40 minutes.
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Page 23: Maintenance
Dry before re-assembling. • Clean the blower wheel with a brush and vacuum. Do not let dirt from cleaning get pulled into the blower. Copper-fin II/IIE Boiler, Water Heater and Pool Owner maintenance (see the User’s Information Manual for instructions) Daily... -
Page 24: Address Reported Problems
Copper-fin II/IIE Boiler, Water Heater and Pool Combustion air filter This appliance has a standard air filter located at the combustion air inlet at the rear of the appliance. This filter helps ensure clean air is used for the combustion process. - Page 25 Ensure that the reason for relief valve weeping is the valve and not over-pressurization of the system due to expansion tank waterlogging or undersizing. Copper-fin II/IIE Boiler, Water Heater and Pool (continued) Inspect/replace hot surface igniter This unit uses a proven hot surface ignition module and a hot surface igniter.
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Page 26: Check Control Settings
If improper flame is observed, examine the venting system, ensure proper gas supply and adequate supply of combustion and ventilation air. Copper-fin II/IIE Boiler, Water Heater and Pool Check flue gas passageways Any sign of soot around the refractory, at the burners, or in the areas between the fins on the copper heat exchanger indicates a need for cleaning. - Page 27 If present, the heat exchanger must be cleaned. Reference the Heat Exchanger Cleaning procedures in this manual. Copper-fin II/IIE Boiler, Water Heater and Pool (continued) Checking combustion air pressure The combustion air fans are factory pre-set and should not require adjustment in most cases.
- Page 28 Gas manifold pressures may be checked with the use of a manometer. Follow the steps in the Checking Combustion Air Pressure Section prior to checking the manifold pressures. Copper-fin II/IIE Boiler, Water Heater and Pool Checking manifold gas pressure Turn the appliance power switch to the “OFF” position.
- Page 29 Maintenance Figure 2-4_Measuring manifold gas pressure MANIFOLD PRESSURE MANOMETER MODEL 402 - 752 992 - 2072 Copper-fin II/IIE Boiler, Water Heater and Pool (continued) PRESSURE REGULATOR ADJUSTMENT (UNDER CAP SCREW) INLET OUTLET VALVE CONTROL KNOB TABLE 2B Net Manifold Pressure...
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Page 30: Review With Owner
16. Reassemble all gas and water piping. Test for gas leaks. 17. Reassemble outer jacket panels. 18. Cycle the appliance and check for proper operation. Copper-fin II/IIE Boiler, Water Heater and Pool HEAT EXCHANGER Figure 2-5_Location of the Heat Exchanger Inside Jacket Review with owner 1. -
Page 31: Troubleshooting
Refer to the Gas Connections Section of the Installation and Operation Manual for detailed information concerning the gas supply. Copper-fin II/IIE Boiler, Water Heater and Pool Check control module fuses NOTICE Turn OFF the power to the appliance at the external line switch. -
Page 32: Table 3A - Troubleshooting Chart - No Display
- Boiler controlled by BMS. - Outlet temperature too high. - Delta T too high. Copper-fin II/IIE Boiler, Water Heater and Pool CAUSE • Check external line switch, fuse, or breaker. • Check position of ON/OFF switch. Turn switch to the ON position. -
Page 33: Checking Temperature Sensors
(Wire Color - W and Y) Temperature Resistance Temperature Resistance Temperature Resistance Temperature Resistance 19,553 12,690 8,406 5,715 3,958 2,786 Table 3C Outdoor Air Sensor Resistance vs. Temperature Temperature Copper-fin II/IIE Boiler, Water Heater and Pool (continued) 2,004 1,464 1,084 Resistance Temperature 490,813 336,606 234,196... -
Page 34: Table 3D - Troubleshooting Chart - Noisy System
Relief Valve - Improperly sized expansion tank. Opening - Outlet water temperature in excess of 210°. Copper-fin II/IIE Boiler, Water Heater and Pool CAUSE • Refer to the Gas Connections Section of the Installation information concerning the gas supply. -
Page 35: Table 3E - Troubleshooting Chart - Fault Messages
The main control board has received a call for heat too quickly after the previous call for heat has ended. Anti-cycling Copper-fin II/IIE Boiler, Water Heater and Pool (continued) DESCRIPTION • Reset the pressure switches. • Measure the supply gas pressure to determine •... - Page 36 The main control board has detected an Flame CKT internal fault. Error Copper-fin II/IIE Boiler, Water Heater and Pool CORRECTIVE ACTION • Inspect igniter and associated wiring for damage and connection. Reference page 25 of this manual for removal and cleaning procedure.
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Page 37: Corrective Action
The outlet water temperature has exceeded the setting of the automatic reset high limit. Auto Reset High Limit Copper-fin II/IIE Boiler, Water Heater and Pool (continued) DESCRIPTION • Check for proper electrical grounding of unit. • Check incoming supply gas pressure. Refer to the •... - Page 38 Press the RESET button on the SMART SYSTEM display to reset.) Copper-fin II/IIE Boiler, Water Heater and Pool DESCRIPTION • Verify setting of adjustable high limit. • Verify that the system is full of water and that all air has been properly purged from the system.
- Page 39 Press the RESET button on the SMART SYSTEM display to reset.) Sensors equipped with an internal limit (such as the Lochinvar Squire Tank Open limit has opened due to temperature (195°F) or the sensor has become disconnected. APS Open...
- Page 40 External control is cycling too often. Rem Ctrl Flt Copper-fin II/IIE Boiler, Water Heater and Pool DESCRIPTION • Verify that the system is full of water and that all air • Verify that the appliance is piped properly into the Section of the Installation and Operation Manual for the proper piping methods.
- Page 41 Service Blk 120 VAC input to the main control board has dropped below 100 VAC. Low Voltage Copper-fin II/IIE Boiler, Water Heater and Pool (continued) DESCRIPTION • Press the ENTER/RESET button on the Smart • Establish a heating load to remove heat from the •...
- Page 42 The main control board has detected an internal fault. The main control board has detected an No Error Stored internal fault. Copper-fin II/IIE Boiler, Water Heater and Pool DESCRIPTION • Cycle main power. • Replace the main control board. • Cycle main power.
- Page 43 NOTES...
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Page 44: Revision Notes
Revision Notes: Revision A (ECO #C08226) initial release. C(F,H,P)X-SER Rev A 6/11...