Lochinvar 502 - 2072, 402 - 2072 User Manual

C(F,H,P)X-SER Rev B

Copper-fin II/IIE

Boiler, Water Heater

and Pool Heater

Service Manual

Models: 402 - 2072

(Boiler & Water Heater)

Models: 502 - 2072

(Pool Heater)

 WARNING

Save this manual for future reference.

This manual must only be used
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.

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 ...................................................... 5

Control Inputs ............................................................... 6

Control Outputs ............................................................. 7

General Operation ........................................................ 8

Sequence of Operation ................................................. 9-10

Display Panel Menu Access ............................................ 11

Display Panel Parameter Access ..................................... 12

Parameter Table.......................................................... 13-14

Viewable and Changeable Control Parameters .......... 15-22

Hazard definitions

2. MAINTENANCE

Maintenance and Annual Startup ................................ 23-30

3. TROUBLESHOOTING

Before Troubleshooting .................................................... 31

Check Control Module Fuses .......................................... 31

Table 3A - Troubleshooting Chart - No Display ............... 32

Checking Temperature Sensors ...................................... 33

Table 3D - Troubleshooting Chart - Noisy System .......... 34

Table 3E - Troubleshooting Chart - Fault Messages .. 35-42

Revision Notes .................................................. Back Cover

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 in death or serious
injury.

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious
injury.

CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate
injury.

CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not
avoided, may result in property damage.

NOTICE indicates special instructions on installation, operation, or maintenance that are important but not
related to personal injury or property damage.

2

Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual

Please read before proceeding

 WARNING

NOTICE

Installer – Read all instructions, including
this manual and the Installation and
Operation Manual, before installing.
Perform steps in the order given.

User – This manual is for use only by a
qualified heating installer/service technician.
Refer to the User’s Information Manual for
your reference.

Have this appliance serviced/inspected by a
qualified service technician at least annually.

Failure to comply with the above could
result in severe personal injury, death or
substantial property damage.

When calling or writing about the appliance
– Please have the appliance model and serial
number from the appliance’s rating plate.

Consider piping and installation when
determining appliance location (see the
Installation and Operation Manual).

Any claims for damage or shortage in
shipment must be filed immediately
against the transportation company by the
consignee.

When servicing appliance –

• To avoid electric shock, disconnect electrical supply
before performing maintenance.

• To avoid severe burns, allow appliance to cool before
performing maintenance.

Appliance operation –

• Do not block flow of combustion or ventilation air to
the appliance.

• Should overheating occur or gas supply fail to shut off,
do not turn off or disconnect electrical supply to
circulator. Instead, shut off the gas supply at a location
external to the appliance.

• Do not use this appliance if any part has been under water.
The possible damage to a flooded appliance can be
extensive and present numerous safety hazards. Any
appliance that has been under water must be replaced.

Appliance water –

• Thoroughly flush the system (without appliance
connected) to remove sediment. The high-efficiency
heat exchanger can be damaged by build-up or
corrosion due to sediment.

• Do not use petroleum-based cleaning or sealing
compounds in the appliance system. Gaskets and seals in
the system may be damaged. This can result in
substantial property damage.

• Do not use “homemade cures” or “appliance patent
medicines”. Serious damage to the appliance, personnel,
and/or property may result.

Handling ceramic fiber materials

REMOVAL OF COMBUSTION CHAMBER LINING

 WARNING

The combustion chamber insulation in this
appliance contains ceramic fiber material.
Ceramic fibers can be converted to cristobalite
in very high temperature applications.
The International Agency for Research on
Cancer (IARC) has concluded, “Crystalline
silica in the form of quartz or cristobalite
from occupational sources is carcinogenic
to humans (Group 1).” Normal operating
temperatures in this appliance are below the
level to convert ceramic fibers to cristobalite.
Abnormal operating conditions would have
to be created to convert the ceramic fibers in
this appliance to cristobalite.

The ceramic fiber material used in this
appliance is an irritant; when handling
or replacing the ceramic materials it is
advisable that the installer follow these safety
guidelines.

Avoid breathing dust and contact with

skin and eyes.

• Use NIOSH certified dust respirator (N95).

• Wear long-sleeved, loose fitting clothing, gloves, and eye

Apply enough water to the combustion chamber lining to

 Remove the combustion chamber lining from the appliance

 Wash potentially contaminated clothes separately from

NIOSH stated First Aid.

 Eye: Irrigate immediately.
 Breathing: Fresh air.

This type of respirator is based on the OSHA
requirements for cristobalite at the time this
document was written. Other types of respirators may
be needed depending on the job site conditions.
Current NIOSH recommendations can be found on
the NIOSH website at http://www.cdc.gov/niosh/
homepage.html. NIOSH approved respirators,
manufacturers, and phone numbers are also listed on this
website.

protection.

prevent airborne dust.

and place it in a plastic bag for disposal.

other clothing. Rinse clothes washer thoroughly.

3

Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual

What is in this manual?

Service

The Copper-fin 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 appliance operates

• How the control module operates

• Access modes -- user and installer

• Sequence of operation -- Domestic Hot Water
(DHW)/space heating

Control panel menu access

• Accessing programming mode and locating menus
(See separate guides covering the ModBus and PC interfaces)

Control panel parameter access

• Accessing and changing parameters from the display panel

Quick start information -- parameter table

• An index of available adjustments and readouts, where to
access them and where to find detailed information.

Maintenance

• Service and maintenance schedules

• Address reported problems

• Inspect appliance area and appliance interior

• Check all piping for leaks

• Flue vent system and air piping

• Combustion air filter

• Check water system

• Check expansion tank

• Check relief valve

• Check igniter

• Check all appliance wiring

• Flame inspection

• Check flue gas passageways

• Inspect and clean burner

• Checking combustion air pressure

• Checking manifold gas pressure

• Cleaning heat exchanger

• Review with owner

Troubleshooting

• Troubleshooting table - No display

• Checking temperature sensors

• Troubleshooting table - Noisy system

• Troubleshooting table - Fault messages displayed on
Operator Interface

Copper-fin operation

• A: General

• B: Temperature Settings

• C: Data Logging

• D: Functions

• E: DHW Settings

• F: Outdoor Air Reset

• G: Anti-cycling

• H: Control Modes

• I: Cascade

• J: Building Management System (BMS)

• K: Pumps

• L: Service Notification

4

1 Service

The Copper-fin display

• Hold 5 seconds to enter code
Input Mode (Menu Mode)

• Press to move up one level
in Menu Mode or to exit
Menu Mode

Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual

• Press to turn heater off or back on

• Press to select a menu item

• Press after parameter programming
to store parameter data

• Press to exit Service Mode

MENU/EXIT

DISPLAY SCREEN

ENTER/RESET

• Press to change boiler water
temperature and/or tank water
temperature set point during
normal operation

• Press to change displayed data
values in Menu Mode

• Press to navigate through menu
listing in Menu Mode

TXENSUOIVERPNWODPU

• Press to toggle display during normal
operation to show outlet and return
temperatures, fan speed, flame signal, etc.

• Press to toggle between digits when
entering access code or between hour,
minutes, etc., when entering date and time

• Press and hold both to enter Service Mode

5

1 Service

Control inputs

OUTDOOR SENSOR
(OPTIONAL)

SYSTEM SUPPLY/
ENABLE SENSOR
(OPTIONAL)

SYSTEM RETURN/
POOL SENSOR
(OPTIONAL ON BOILER)
(STD ON POOL HEATER)

SYSTEM PUMP SPEED
(OPTIONAL)

CASCADE

DHW THERMOSTAT
(OPTIONAL)

ROOM THERMOSTAT/
ZONE CONTROL
(OPTIONAL)

SEQUENCER BUILDING
MANAGEMENT S YSTEM
(FIELD PROVIDED)

LOUVER PROVING SWITCH
(FIELD PROVIDED)

TANK SENSOR
(OPTIONAL)

MODBUS

INLET TEMPERATURE
SENSOR

OUTLET TEMPERATURE/
LIMIT SENSOR

LOW WATER CUTOFF
(OPTIONAL)

GAS PRESSURE SW ITCH
(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 Service Manual

SENSOR
CONNECTION
BOARD
(BOILER AND
POOL HEATER
ONLY)

SMART
SYSTEM
CONTROL
BOARD

MODBUS

BOARD

(OPTIONAL)

LOW

VOLTAGE

CONNECTION

BOARD

6

1 Service (continued)

Control outputs

Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual

MODBUS

BOARD

(OPTIONAL)

SMART

SYSTEM

CONTROL

BOARD

LOW

VOLTAGE

CONNECTION

BOARD

MODBUS

0-10V

POWER

CASCADE

THREE WAY VALVE

(OPTIONAL ON BOILER)

(STD ON POOL HEATER)

LOUVER RELAY

BUILDING

MANAGEMENT

SYSTEM

RUN TIME CONTACTS

ALARM CONTACTS

ALARM

(OPTIONAL)

HEATER PUMP

(BOILER ONLY)

SYSTEM PUMP

RELAY

DHW PUMP RELAY

(BOILER)

DHW PUMP

(WATER HEATER)

INDICATES CONNECTIONS MADE TO THE LINE VOLTAGE TERMINAL STRIP LOCATED IN THE CONTROL PANEL AREA

HOT SURFACE

IGNITER

BLOWER

GAS VALVES

DISPLAY PANEL

PC INTERFACE

(OPTIONAL)

7

1 Service

General Operation

Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual

How the appliance operates

The Copper-fin uses a finned copper tube heat exchanger to
transfer heat from the flue products to the water. An electronic
control module monitors various inputs to initiate a call for
heat. The blower provides both primary and secondary air to
the burner and forces the flue products out of the combustion
chamber and into the vent system. The control module
regulates the blower speed (on B9 and M9 models) to control
the firing rate of the appliance. The modulating gas valve
monitors the amount of combustion air being pulled into the
blower and regulates the amount of gas supplied, which then
mixes with the combustion air and is supplied to the burner.

How the control module operates

The Copper-fin control module receives input from appliance
sensors. The control module activates and controls the
blower and gas valves to regulate heat input and switches
heater, DHW and system pumps on and off as needed. The
user/installer programs the module to meet system needs by
adjusting control parameters. These parameters set operating
temperatures and heater operating modes. Appliance operation
can be based on heater outlet water temperature, heater return
water temperature, system supply temperature, system return
temperature or tank temperature, depending on the parameter
setting.

Sequence of operation

Table 1A shows control module normal sequences of operation
for space heating and DHW operation. The combined operation
sequence is for a typical application, programmed to provide
DHW priority.

Access modes

User

The user can adjust space heating set point using the UP
and DOWN buttons at any time during normal operation.
By entering the USER code (0704), the user can also change
temperature units, time and date, and night setback settings.
In user mode, the following parameters can be viewed but not
changed: Heater outlet water temperature in DHW mode;
heater model number; software version; total operating hours,
and total cycles.

Installer

Most parameters are available only to the installer, accessible
only by entering the installer access code (5309).

Saving parameters

To save parameters and exit programming:

Press the ENTER/RESET button, then the MENU/EXIT button
3 times.

To keep parameter settings only for a current operating cycle:

Press the MENU/EXIT button 3 times after making all desired
parameter changes.

To enter a parameter and continue programming:

Press the MENU/EXIT button 1 time to return to the parameter
listings; press again to return to the menu listings. Remember
to press the ENTER/RESET button when finished programming
in order to save the changes made.

8

Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual

1 Service (continued)

Sequence of operation

Table 1A_Sequence of Operation - Space Heating and DHW

OPERATION DISPLAY

1. The manual reset high limit (optional) must be closed before
any action will take place.

2. Upon a call for heat the control turns on the appropriate
pumps (system and boiler pumps for space heating; DHW
pump for DHW call). The flow switch and low water cutoff
(if equipped) must close.

3. • The gas pressure switch(es) (if equipped) must close.

• The louver proving input must close.

• If the air pressure switch is open, the prepurge cycle then
begins by starting the combustion blower. Once started,
the air pressure switch must close.

4. After the 15 second prepurge, the blower slows down and
the hot surface igniter (HSI) is energized. The HSI is heated
for at least 20 seconds.

5. Once the HSI is hot, the trial for ignition begins with the
opening of the gas valve.

HTR: Standby
OUT: 123.8F(129)

HTR: Standby
OUT: 123.8F(129)

HTR: Standby
OUT: 123.8F(129)

HTR: PREPURGE
OUT: 123.9F(129)

HTR: IGNITION
OUT: 123.9F(129)

6. If the SMART SYSTEM control does not sense flame, then
it will lock out.

7. If the SMART SYSTEM control senses flame,
it will fire the burner to maintain the set point. The
stages will fire as required to hold the actual temperature at
the set point. If the boiler lights due to a space heating call for
heat, and the ramp delay function is active (default is
disabled), the stages will be held to a series of increasing
limits after the burner has lit.

8. If the space heating call for heat is active, and the DHW
thermostat closes, the control will turn on the DHW pump,
wait 2 seconds, and then turn off the boiler pump. This will
divert the hot water away from the heating zone(s) and send
it to the DHW tank instead. The control will then fire the
stages to maintain the outlet temperature to the DHW boiler
set point.

HTR: POSTPURGE, PREPURGE
OUT: 123.9F(129)

HTR: RUN STG: 1
OUT: 124.8F(129)

HTR: DHW STG 123
OUT: 177.8(180)

9

Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual

1 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 after 2 seconds, and resume firing based on the
space heating set point. As long as both the space heating
and DHW calls for heat remain active, the control will switch
back and forth between the two modes until one of them is
satisfied.

10. Once both calls for heat are satisfied, the control will turn
off the burners. The blower will remain on for the
30 second postpurge cycle. Any pumps that are running
will continue to run for their respective pump delay times,
then turn off.

HTR: RUN STG 12

OUT: 123.0F(129)

HTR: POSTPURGE

OUT: 127.4F(129)

11. Boiler pump off, system pump continues its delay if
longer.

12. System pump off.

HTR: Standby

OUT: 124.7F(129)

HTR: Standby

OUT: 122.9F(129)

10

Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual

1 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.

11

Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual

1 Service

Display panel parameter access

Table 1C_This is a typical example of accessing a parameter, shown for parameter K2, SH pump delay

Cascade
BMS

12

Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual

1 Service (continued)

Parameter table

Table 1D_This table lists SMART SYSTEM control module parameters and where to access them

Menu

A

GENERAL

B

SETTINGS

TEMPERATURE

C

DATA

LOGGING

D

FUNCTIONS

E

DHW SETTINGSOUTDOOR RESET

F

Sub

Item

1 User Code 15 Yes Yes Yes Yes
2 Time and Date 15 Yes Yes Yes Yes
3 Software Version 15 Yes No Yes Yes
4 Temperature Units 15 Yes Yes Yes Yes
5 SH Night Setback Offset 15 Yes Yes Yes Yes
6 SH Night Setback Times 15 Yes Yes Yes Yes
7 DHW Night Setback Offset 15 Yes Yes Yes Yes
8 DHW Night Setback Times 15 Yes Yes Yes Yes
1 SH User Setpoint 15 Yes Yes Yes Yes
2 Minimum SH User Setpoint 15 No No Yes Yes
3 Maximum SH User Setpoint 16 No No Yes Yes
4 SH Offset 16 No No Yes Yes
5 SH Differential 16 No No Yes Yes
6 Manual Reset High Limit 16 Yes Yes Yes Yes
7 Auto Reset High Limit 16 Yes Yes Yes Yes
1 Hours Running SH 16 No No Yes Yes
2 Hours Running DHW 16 No No Yes Yes
3 Burner Cycles 16 No No Yes Yes
4 Last 10 Lockouts 16 No No Yes Yes
1 Reset Last 10 Lockouts 16 No No Yes Yes
2 Service Mode Delay 16 No No Yes Yes
3 Display Timeout 16 No No Yes Yes
4 Bypass Valve Time 16 No No Yes Yes

5 Freeze Protection Pump On 17 No No Yes Yes
6 Freeze Protection Burner On 17 No No Yes Yes
7 Freeze Protection Differential 17 No No Yes Yes
1 Tank Setpoint 17 Yes Yes Yes Yes
2 DHW Boiler Setpoint 17 Yes Yes Yes Yes
3 SH/DHW Switching Time 17 No No Yes Yes
4 DHW/SH Switching Time 17 No No Yes Yes
5 Tank Offset 17 No No Yes Yes
6 Tank Differential 17 No No Yes Yes
1 Low Outdoor Temperature 18 No No Yes Yes
2 High Outdoor Temperature 18 No No Yes Yes
3 Setpoint at Low Outdoor Temperature 18 No No Yes Yes
4 Setpoint at High Outdoor Temperature 18 No No Yes Yes
5 Outdoor Shutdown Setpoint 18 Yes Yes Yes Yes
6 Outdoor Shutdown Differential 19 Yes Yes Yes Yes
7 Shfit Reset Curve 19 No No Yes Yes
8 Boost Temperature 19 Yes Yes Yes Yes
9 Boost Time 19 Yes Yes Yes Yes

Description

See

Page

User Access Installer Access

Display Modify Display Modify

13

Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual

1 Service

Parameter table (continued)

Table 1D_(continued from previous page) This table lists SMART SYSTEM control module parameters and where to
access them

ANTI-

CYCLING

MODES

CONTROL

CASCADEBMSPUMPS

SERVICE

NOTIFICATION

Menu

G

H

I

J

K

L

Sub

Item

1 Anti-cycle Delay 19 No No Yes Yes
2 Anti-cycle Override Differential 19 No No Yes Yes
3 Min On/Off Time Stages 1, 3 19 No No Yes Yes
4 Delay Between Stages 1, 3 19 No No Yes Yes
1 Controlling Sensor 20 No No Yes Yes
2 Enable Input (Active / Inactive) 20 No No Yes Yes
3 BMS Input (Active / Inactive) 20 No No Yes Yes
4 Cascade (Active / Inactive) 20 No No Yes Yes
5 Sequencer 20 No No Yes Yes
6 ModBus (Active / Inactive) 20 No No Yes Yes

7 ModBus Timeout 20 No No Yes Yes
1 Cascade Address 21 No No Yes Yes
2 Max. Outlet Set point 21 Yes Yes Yes Yes
3 Cascade Offset 21 No No Yes Yes
4 Cascade Differential 21 No No Yes Yes
1 BMS Type 21 No No Yes Yes
2 Voltage at Minimum 21 No No Yes Yes
3 Voltage at Maximum 21 No No Yes Yes
4 Power at Low Voltage 21 No No Yes Yes
5 Power at High Voltage 21 No No Yes Yes
6 Setpoint at Low Voltage 21 No No Yes Yes
7 Setpoint at High Voltage 22 No No Yes Yes
8 Voltage to Start CFH 22 No No Yes Yes
9 Voltage Differential CFH 22 No No Yes Yes
1 System Pump Delay 22 No No Yes Yes
2 Boiler Pump Delay 22 No No Yes Yes
3 DHW Pump Delay 22 No No Yes Yes
4 System Pump Mode 22 No No Yes Yes
1 Service Calendar Time (months) 22 No No Yes Yes

2 Service Run Time (hours) 22 No No Yes Yes
3 Service Cycles 22 No No Yes Yes
4 Reset Service Reminder 22 No No Yes Yes
5 Personality Plug 22 No No Yes Yes

Description

See

Page

User Access Installer Access

Display Modify Display Modify

14

Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual

1 Service (continued)

Viewable and changeable control parameters

CAUTION

Before changing parameters, note the
settings so that the unit can be returned to
its original operating parameters.

A: General

A1: User code

The User Code allows the user to access and change a limited
number of control parameters. The access code can be changed
by the user or the installer to a code of their choosing. To
change the code, parameter A1 must be accessed. The default
code is 0704. The code can be changed one digit at a time by
using the arrow keys on the display.

A2: 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 unit is first installed or any time
the unit has been powered off for more than 30 days. To set
the clock, parameter A2 must be accessed. The date and time
are displayed as “YY:MM:DD W hh:mm”. YY = year, MM =
month, DD = date, W = day (1 = Monday, 2 = Tuesday, etc.),
hh = hour (24 hour time; 2:00 PM = 14:00), mm = minutes.

NOTICE

A3: Software version

The software version allows the user to view the software version
in use by the control. This software controls the operation of
the unit. When a new software version becomes available, the
existing control can be replaced with a new control to update
the software.

A4: Temperature units

The control can be configured to display temperature in either
°C or °F. This parameter can be changed by the user or the
installer by accessing parameter A4. The default is °F.

A5: SH Night setback offset

Once the internal clock has been set correctly, the SH night
setback feature can be used to program a lower set point. The
value of this parameter will be subtracted from the normal set
point to determine the set point used during night setback.
This parameter can be changed by the user or the installer
by accessing parameter A5. The temperature range for this
parameter is 0°F to 90°F (50°C). The feature is turned off with
a setting of 0°F. The default value is 0°F.

The internal clock does not adjust for
Daylight Savings Time and therefore, will
require a manual adjustment.

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. To keep night setback
active through the entire day, set the on and off time to the same
time, and after 12:00 p.m. The default times for each day will be
08:00 (OFF) and 18:00 (ON).

A7: DHW Night setback offset

Once the internal clock has been set correctly, the DHW night
setback feature can be used to program a lower SH set point
during various times of the week. The value of this parameter
will be subtracted from the normal set point to determine the
set point used during night setback. This parameter can be
changed by the user or installer by accessing parameter A7. The
temperature range for this parameter is 0°F to 90°F (50°C). The
default value is 0°F.

A8: DHW Night setback times

If parameter A7 is set to anything other than 0°F, the DHW
night setback feature becomes active. This will require start
and stop times to be programmed for the days that reduced
temperatures are required. These times can be changed by the
user or the installer by accessing parameter A8. Each day of the
week (Monday through Sunday) will have an on and off time. If
you wish to skip a day, set the on and off times to the same time,
and prior to 12:00 p.m. To keep night setback active through
the entire day, set the on and off times to the same time and
after 12:00 p.m.

B: Temperature settings (boiler only)

B1: SH Set point user

The SH set point user sets the water temperature or pool
temperature set point for fixed operation, or the maximum
temperature set point when the outdoor air sensor is used.
This parameter can be changed by the user or the installer
by accessing parameter B1. The temperature range of this
parameter is 60°F (15°C) to 230°F (110°C). The default value
is 80°F (27°C).

B2: SH Minimum set point

The SH minimum set point sets the minimum water temperature
set point that can be used for space heating and pool heater
operation. The user or installer will not be able to program
the control with a lower SH set point. This parameter can only
be changed by the installer by accessing parameter B2. The
temperature range of this parameter is 32°F (0°C) to 230°F
(110°C) (space heating) or 32°F (0°C) to 105°F (40°C) (pool
heater). The default value is 70°F (21°C).

A6: SH Night setback times

If parameter A5 is set to anything other than 0°F, the night
setback feature becomes active. This will require start and stop
times to be programmed for the days that reduced temperatures
are required. These times can be changed by the user or the
installer by accessing parameter A6. Each day of the week
(Monday through Sunday) will have an on and off time.

15

1 Service

Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual

B3: SH Maximum set point

The SH maximum set point sets the maximum water
temperature set point that can be used for space heating. The
user or installer will not be able to program the control with a
higher SH set point. This parameter can only be changed by the
installer by accessing parameter B3. The temperature range of
this parameter is 32°F (0°C) to 230°F (110°C) (space heating)
or 32°F (0°C) to 105°F (40°C) (pool heater). The default value
is 220°F (104°C) (space heating) or 105°F (55°C) (pool heater).

B4: SH Offset

The SH offset sets how many degrees above set point the
temperature has to go before the unit will shut off. This
parameter can only be changed by the installer by accessing
parameter B4. The temperature range of this parameter is 0°F
(0°C) to 54°F (30°C). The default value is 10°F (5°C) (boiler) or
2°F (1°C) (pool heater).

B5: SH Differential

The SH differential sets how many degrees below the turn off
temperature the temperature has to go before the unit will
turn on. This parameter can only be changed by the installer
by accessing parameter B5. The temperature range of this
parameter is 0°F (0°C) to 54°F (30°C). The default value is 20°F
(11°C) (boiler) or 4°F (2°C) (pool heater).

B6: Manual reset high limit

The SMART SYSTEM control includes an integrated manual
reset high limit (MRHL) feature, based on the outlet temperature.
The set point for the MRHL is adjusted using parameter B6.
The temperature range of this parameter is 32°F (0°C) to 210°F
(99°C) for water heaters and pool heaters, or 240°F (115°C) for
boilers. The default value is 210°F (99°C) for boilers and water
heaters, or 200°F (93°C) for pool heaters.

B7: Auto reset high limit

The SMART SYSTEM control also includes an integrated auto
reset high limit (ARHL) feature, based on outlet temperature.
The ARHL set point is fixed at 205°F (96°C) for water heaters,
and 185°F (85°C) for pool heaters. For boilers, the temperature
range of this parameter is 32°F (0°C) to 235°F (113°C). The
default value is 200°F (93°C).

C: Data logging

C1: Hours running SH

The hours running SH parameter shows the total number of
hours the unit has been in the SH firing mode. This parameter
can be viewed by the user and the installer by accessing
parameter C1.

C2: Hours running DHW

The hours running DHW parameter shows the total number
of hours the unit has been in the DHW firing mode. This
parameter can be viewed by the user and the installer by
accessing parameter C2.

C3: Burner cycles

The burner cycles parameter shows the total number of times
the unit has attempted to fire. This parameter can be viewed by
the user and the installer by accessing parameter C3.

C4: Show last 10 lockouts

The control will log the 10 most current lockouts with the date
and time the lockout occurred. This parameter can be viewed

by the user and the installer by accessing parameter C4.

D: Functions

D1: Reset last 10 lockouts

The reset last 10 lockouts parameter allows the lockout counter
to be reset to 0. This parameter can only be cleared by the
installer by accessing parameter D1. Once accessed, press the

RESET key to clear the counter.

D2: Service mode delay

By pressing the PREVIOUS and NEXT keys on the front of
the display for five (5) seconds, the control will be placed
in Service Mode. This will override all other heat demands.
The Service Mode allows the installer to set the unit to either
maximum firing rate or minimum firing rate for the purpose
of combustion analysis. The delay sets the length of time the
unit will stay in the Service Mode if no keys have been pressed
before going back to its original state. This parameter can only
be changed by the installer by accessing parameter D2. The
time range of this parameter is 0 to 40 minutes. The default
value is 20 minutes.

D3: Display timeout

Whenever a button on the display is pushed, the backlight on

the LCD is turned on, and a delay timer is reset. When this
timer expires, the backlight turns off, and the display returns
to the first Status Screen. The value of this timer can be
adjusted using parameter D3. The range of this timer is 0 to
255 seconds. Setting this parameter to 0 disables the backlight.
The default value is 60 seconds.

D4: Bypass valve time

In low temperature systems, a 3-way bypass valve can be
installed between the outlet and the inlet of the heater (see
Installation and Operation Manual). The SMART SYSTEM
control can be set to automatically control this valve to maintain
the inlet temperature above the condensing temperature.
Different valves require different amounts of time to open
and close completely. The SMART SYSTEM controls need to
know how long this takes in order to control the bypass valve
properly. This time can be adjusted using parameter D4. The
range of this parameter is 0 to 255 seconds. The default value
is 20 seconds.

16

1 Service (continued)

Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual

D5: Freeze protection pump on

In order to prevent the water in the heater from freezing, the
SMART SYSTEM control turns on the boiler pump whenever
the inlet temperature goes below the minimum temperature.
This temperature can be adjusted by using parameter D5. The
range of this parameter is 32°F (0°C) to 104°F (40°C). The
default value is 45°F (7°C).

D6: Freeze protection burner on

If the inlet temperature continues to drop after strating
the pump (see Freeze Protection Pump On), and the inlet
temperature goes below a second minimum temperature, the
first stage will fire. This second temperature can be adjusted by
using parameter D6. The temperature range of this parameter
is 32°F (0°C) to 104°F (40°C. The default value is 37°F (3°C).

D7: Freeze protection differential

Once the pump has turned on, this parameter determines how
much the inlet temperature must rise before the pump turns
off. Similarly, once Stage 1 has turned on, this parameter also
determines how much the inlet temperature must rise before
Stage 1 turns back off. This temperature differential can be
adjusted using parameter D7. The temperature range of this
parameter is 0° to 72°F (40°C). The default temperature is 5°F
(3°C).

E4: DHW/SH switching time (boiler only)

The time that the SMART SYSTEM control services a DHW
demand before returning to the SH demand is set by parameter
E4. The range of this parameter is 0 to 240 minutes. Setting
this parameter to 0 disables the switching function. The default
value of this parameter is 30 minutes.

E5: Tank offset (water heater only)

The tank offset is the number of degrees the DHW tank
temperature must go above the tank set point before the water
heater will turn off. To adjust this value, access parameter E5.
The temperature range of this parameter is 0° to 10°F (5°C).
The default value is 4°F (2°C).

E6: Tank differential

The tank differential is the number of degrees the DHW tank
temperature must go below the tank set point before the heater
or boiler will start to heat the DHW tank. To adjust this value,
access parameter E6. The temperature range of this parameter
is 0° to 40°F (22°C). The default value is 6°F (3°C).

E: DHW settings

E1: DHW tank set point

When a temperature sensor is installed in the DHW tank, the
DHW tank set point sets the target temperature of the water
in the tank. The user or installer can adjust this set point
by accessing parameter E1. The temperature range of this
parameter is 60°F (15°C) to 190°F (88°C). The default value is
120°F (49°C).

E2: DHW boiler set point (boiler only)

When an indirect DHW call for heat becomes active, the control
will use the DHW boiler set point to determine the firing rate
of the unit based on the actual outlet water temperature.
This parameter can be changed by the installer by accessing
parameter E2. The temperature range of this parameter is 32°F
(0°C) to 261°F (127°C). The default value is 180°F (82°C).

E3: 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. The time that the
control services the SH demand before switching to the DHW
demand can be adjusted by using parameter E3. The range of
this parameter is 0 to 240 minutes. Setting this parameter to
0 disables the switching function. The control will service the
DHW demand until it ends, then return to the SH demand (if
active). The default value of this parameter is 30 minutes.

17

1 Service

Figure 1-1_Outdoor Air Reset Curve

Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual

F: Outdoor air reset (boiler only)

Outdoor air reset operation

When the outdoor air sensor is installed, the control will
calculate the water temperature set point based on the outdoor
air temperature. As the outdoor air temperature drops, the
water temperature set point increases. This feature allows
the unit to be more efficient in periods of mild weather, see
FIG. 1-1 on page 17.

F1: Minimum air temperature

When the outdoor air temperature drops to this point, the
water temperature will be at its maximum setting (FIG. 1-1). The
set point will continue to increase as the outdoor temperature
drops below this setting. The water temperature will be limited
by the user set point. This parameter can be changed by the
installer by accessing parameter F1. The temperature range
of this parameter is -22°F (-30°C) to 86°F (30°C). The default
value is 25°F (-4°C).

F2: Maximum air temperature

When the outdoor air temperature rises to or above this
point, the water temperature will be at its minimum setting
(FIG. 1-1). This parameter can be changed by the installer
by accessing parameter 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).

18

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. 1-1). This
parameter can be changed by the installer by accessing
parameter F3. The temperature range of this parameter
is 32°F (0°C) to 248°F (120°C). The default value is 180°F
(82°C).

F4: Minimum SH set point

When the outdoor temperature rises to or above its
maximum setting (F2) the water temperature will be at
this value (FIG. 1-1). This parameter can be changed by
the installer by accessing parameter F4. The temperature
range of this parameter is 32°F (0°C) to 248°F (120°C).
The default value is 70°F (21°C).

F5: Outdoor air shutdown

When the outdoor temperature rises above this point,
the control will block all SH demands (DHW demands
will still be active). This parameter can be changed by
the user or the installer by accessing parameter F5. The
temperature range of this parameter is 32°F (0°C) to 122°F
(50°C). The default value is 80°F (27°C).

1 Service (continued)

Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual

F6: Outdoor air shutdown differential

The outdoor air shutdown differential parameter is the number
of degrees below parameter F5 the outdoor air temperature must
go before the unit will respond to a SH demand. This parameter
can be changed by the user or the installer by accessing
parameter F6. The temperature range of this parameter is 0°F
(0°C) to 90°F (50°C). The default value is 10°F (5°C).

F7: Shift reset curve

The shift reset curve parameter shifts the actual set point above
or below the calculated set point the number of degrees in this
parameter. This parameter can be changed by the installer
by accessing parameter F7. The temperature range of this
parameter is -27°F (-15°C) to 27°F (15°). The default value is
0°F (0°C). This feature will be active if this parameter is set to
anything other than 0°F (0°C).

F8: Boost temperature

If a SH demand lasts longer than the programmed time delay
setting (F9) and there have been no DHW demands, the control
will increase the SH set point by the amount in this parameter.
If the SH demand continues through another time period,
the set point will be increased again. This will continue until
either the SH demand ends, a maximum of 20 increases has
occurred, or the SH user set point has been reached. Once the
SH demand has been satisfied the set point will revert back to
its calculated setting. The boost temperature can be changed by
the installer by accessing parameter F8. The temperature range
of this parameter is 0°F (0°C) to 45°F (25°C). The default value
is 0°F (0°C). This feature will be active if this parameter is set to
anything other than 0°F (0°C).

G2: Anti-cycle override differential

The control will bypass the anti-cycling time if the inlet water
temperature drops too quickly. The control will use the water
temperature at the time it shut off as the starting point. If
the temperature drops below the temperature parameter
the control will abort anti-cycling and allow the unit to fire.
This parameter can be changed by the installer by accessing
parameter G2. The temperature range of this parameter is 0°F
(0°C) to 54°F (30°C). The default value is 10°F (5°C).

G3: Minimum on / off stages 1, 3

Whenever Stage 1 or Stage 3 (if used) starts or stops, a timer is
started. This timer must expire before that stage can turn off
or back on. To adjust this time delay, access parameter G3. The
range of this parameter is 0 to 255 seconds. The default value
is 60 seconds.

G4: Delay between stages 1, 3

Whenever Stage 1 or Stage 3 (if used) turns on, a timer must
expire before another Stage 1 or 3 can turn on, whether in the
same heater, or in another heater in a Cascade. To adjust this
time delay, access parameter G4. The range of this parameter
is 0 to 255 seconds. The default value is 60 seconds.

F9: Boost time

The boost time parameter sets the amount of time that must
elapse with a SH demand before the water temperature set point
will be increased. This parameter can be changed by the installer
by accessing parameter F9. The time range for this parameter is
1 minute to 250 minutes. The default value is 20 minutes.

G: Anti-cycling

G1: Anti-cycle delay

Once a SH demand has been satisfied, a set amount of time must
elapse before the control will respond to a new SH demand. The
control will block the new heat demand and anti-cycling will
be shown in the display until the time has elapsed or the water
temperature drops below parameter G2. This parameter can be
changed by the installer by accessing parameter G1. The time
range for this parameter is 0 minutes to 40 minutes. The default
value is 1 minute.

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1 Service

Figure 1-2_Ramp Delay Interval

Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual

H: Control modes

H1: SH controlling sensor (boiler only)

The SH controlling sensor parameter selects the sensor the
control will use to regulate the boiler firing rate. This parameter
is adjustable by the installer by accessing parameter H1. The
sensor selections are as follows: The outlet sensor regulates the
firing rate based on the outlet water temperature of the unit and
the inlet sensor regulates the firing rate based on the inlet water
temperature of the unit. If the outlet sensor is selected, and
the optional system supply sensor is connected, the control will
regulate the firing rate based on the system sensor temperature.
If the inlet sensor is selected, and the optional system return
sensor is connected, the control will regulate the firing rate
based on the system return sensor. The default sensor is the
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. Second, the 0-10Vdc voltage from a BMS can be used
to generate the call for heat, as well as provide the set point or
modulation level. On boilers, the external contact is connected
to the Stage 1 input on the low voltage connection board. On
water heaters, the external contact is connected to the Tank
Thermostat input on the low voltage connection board. When
a tank sensor is connected, the Tank Thermostat input is not
used. When the call for heat comes from an external contact or
tank sensor, the enable input must be set to active. When the
call for heat comes from the 0-10Vdc input, the enable input
must be set to inactive. This setting is adjustable by the installer
by accessing parameter H2. The default setting is Active.

20

H3: BMS input (active / inactive)

When the building management input is enabled, the control
modulates the unit or the cascade based on the voltage on the
0-10V input on the connection board. The 0-10V input may
control either the modulation of the unit(s), or the set point.
This setting is adjustable by the installer by accessing parameter
H3. The default value is Inactive. See menu Section J to adjust
the parameters that control the BMS operation.

H4: Cascade (active / inactive)

Boilers or water heaters may be part of a group of units
sequenced together. When so connected, each heater must be
programmed to operate as part of the Cascade. This is done
by setting the Cascade to Active. This setting is adjustable by
the installer by accessing parameter H4. The default value is
Inactive.

H5: Sequencer (active / inactive) (boiler only)

The individual stages in the heater can be controlled separately
with an external sequencer. This setting is adjustable by the
installer by accessing parameter H5.

H6: ModBus (active / inactive)

When the optional ModBus board is installed, the heater can be
monitored and controlled by a Building Control System (BCS).
If the heater is to be controlled through ModBus, parameter H6
must be set to ACTIVE. The default value is Inactive.

H7: ModBus timeout

When the heater is being controlled or is receiving temperature
readings through ModBus, the information sent to the heater
must be refreshed periodically. If the heater does not receive new
information after a timeout, it will revert to local temperature
readings and control. This prevents the heater from running for
too long should the ModBus connection be lost. To adjust the
length of this timeout, access parameter H7. The range of this
parameter is 0 to 120 seconds. The default value is 10 seconds.

1 Service (continued)

I: Cascade

Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual

J: Building Management System (BMS)

I1: Cascade address

The boiler designated as the Leader needs to be programmed
with address 0. All the Member boilers require addresses from
1 to 7, and the addresses must be different for each Member.
The addresses can be in any order, regardless of the order in
which the units are wired together. This parameter is adjustable
by the installer by accessing parameter I1. The outdoor air (if
used), system supply sensor, and system return sensor must be
connected to the Leader boiler. The default address is 1.

I2: Max. outlet set point

When the system supply sensor is connected, or the system
supply temperature is provided through ModBus, this parameter
determines the set point used by the individual boilers in a
Cascade. When a boiler is commanded to fire by the Leader
boiler, it will attempt to achieve this temperature at its outlet.
The Leader boiler will limit the modulation of the last boiler to
fire in order to hold the temperature at the system supply sensor
to the user set point. If any of the boiler outlet temperatures
reach the max. cascade set point, the boiler will then modulate
down on its own in order to keep its outlet temperature
within the max. cascade set point. Therefore, this parameter
can be used to limit the outlet temperatures of all the boilers
in a Cascade. Note that this parameter does not apply when
the boiler is heating an indirect DHW tank. This parameter
is adjustable by the installer by accessing parameter I2. The
temperature range for this parameter is 32°F (0°C) - 261°F
(127°C). The default max. cascade set point is 185°F (85°C).

I3: Cascade offset (boilers only)

This parameter determines how much the temperature must
go above set point before the lead boiler will turn off. This
parameter can be adjusted by the installer by accessing parameter
I3. The temperature range for this parameter is 0°F (0°C) - 54°F
(30°C). The default value is 9.9°F (5°C).

I4: Cascade differential (boilers only)

This parameter determines how much the temperature must
go below the turn off temperature (Set point + Offset) before
the lead boiler turns on. This parameter can be adjusted by the
installer by accessing parameter 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).

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. This parameter may be adjusted by the installer by
accessing parameter J1. The default value is Power.

J2: Voltage at minimum

This setting determines the voltage at which the external
signal begins to increase either the modulation or the set
point. Below this voltage, the modulation or set point will
be at their minimum values. This parameter can be adjusted
by the installer by accessing parameter J2. The range for this
parameter is 0V - (J3 - 0.1V). The default value is 2V.

J3: Voltage at maximum

This setting determines the voltage at which the external signal
forces either the modulation or the set point to their maximum
value. This parameter, along with the previous parameter,
determines how much the modulation or set point changes as
the BMS input voltage changes. The modulation or set point
will change in proportion to the change in voltage between the
minimum and maximum voltage settings. This parameter may
be adjusted by the installer by accessing parameter J3. The
range for this parameter is (J2 + 0.1V) - 10V. The default setting
is 10V.

J4: Power at low voltage

This setting determines the modulation of the unit or cascade
when the BMS input voltage is at or below the Voltage at
Minimum setting. This parameter is active only when the
BMS type is set to Power. This parameter may be adjusted
by the installer by accessing parameter J4. The range for this
parameter is 0 - J5. The default value is 20%.

J5: Power at high voltage

This setting determines the modulation of the unit or cascade
when the BMS input voltage is at or above the Voltage at
Maximum setting. This parameter is only active when the
BMS type is set to Power. This parameter can be adjusted
by the installer by accessing parameter J5. The range for this
parameter is J4 - 100%. The default value is 100%.

J6: Set point at low voltage

This setting determines the set point used by the unit or cascade
when the BMS voltage is at or below the Voltage at Minimum
setting. This parameter is only active when the BMS type is set
to Set Point. This parameter can be adjusted by the installer
by accessing parameter J6. The temperature range for this
parameter is 32°F (0°C) - 230°F (110°C) (boilers), 32°F (0°C)
to 190°F (87°C) (water heaters), or 32°F (0°C) to 105°F (40°C)
(pool heaters). The default value is 70°F (21°C).

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1 Service

Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual

J7: Set point at high voltage

This setting determines the set point used by the unit or cascade
when the BMS voltage is at or above the Voltage at Maximum
setting. This parameter is only active when the BMS type is set
to Set Point. This parameter can be adjusted by the installer
by accessing parameter J7. The temperature range for this
parameter is 32°F (0°C) - 230°F (110°C) (boilers), 32°F (0°C)
to 190°F (87°C) (water heaters), or 32°F (0°C) to 105°F (40°C)
(pool heaters). The default value is 190°F (88°C) for water
heaters, 220°F (104°C) for boilers, and 105°F (40°C) (pool
heaters).

J8: Voltage to start CFH

When the Enable input is set to Inactive, this parameter
determines the BMS input voltage at which the unit or cascade
is enabled. When the unit is disabled, the unit will become
enabled when the BMS input voltage rises up to or above this
value. This parameter may be adjusted by the installer by
accessing parameter J8. The range for this parameter is (J9 +

0.1V) - 10V. The default value is 2V.

J9: Voltage differential CFH

When the Enable input is set to Inactive, this parameter
determines the BMS input voltage at which the unit or cascade
is disabled. When the unit is enabled, the unit will become
disabled when the BMS input voltage drops down to or below
the enable voltage minus this value. This parameter may be
adjusted by the installer by accessing parameter J9. The range

for this parameter is 0V - (J8 - 0.1V). The default value is 1V.

K: Circulation pumps

K1: System pump delay

The system pump delay parameter sets the length of time the
system pump (if connected) will run after a SH demand has
been satisfied or outdoor air shutdown begins. This parameter
is adjustable by the installer by accessing parameter K1. The
time range for this parameter is 1 minute to 40 minutes. The
default time is 30 seconds.

K2: SH pump delay

The SH pump delay parameter sets the length of time the boiler
pump will run after a SH demand has been satisfied. This
parameter is adjustable by the installer by accessing parameter
K2. The time range for this parameter is 1 minute to 40
minutes. The default time is 30 seconds.

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. The default time is
30 seconds.

K4: System pump mode (boiler only)

The system pump can be configured to operate in one of two
modes. “CFH” runs the system pump whenever there is a SH
demand. “WWSD” runs the system pump continuously, except
when the boiler is blocked due to outdoor shutdown. To adjust
the System Pump Mode, access parameter K4. The default
mode is CFH.

L: Service Notification

L1: Service calendar time (months)

When the boiler control determines that a scheduled service is
due based on days of installation, the boiler display will alternate
the standard boiler display text with the message SERVICE DUE
every 5 seconds. This parameter is adjustable by the installer by
accessing parameter L1. The time range for this parameter is 0
months to 36 months. The default time is 12 months.

L2: Service runtime (hours)

When the boiler control determines that a scheduled service is
due based on the hours of actual operation, the boiler display
will alternate the standard boiler display text with the message
SERVICE DUE every 5 seconds. This parameter is adjustable
by the installer by accessing parameter L2. The time range for
this parameter is 0 hours to 100,000 hours. The default time is
10,000 hours.

L3: Service cycles

When the boiler control determines that a scheduled service
is due based on the number of boiler cycles, the boiler display
will alternate the standard boiler display text with the message
SERVICE DUE every 5 seconds. This parameter is adjustable
by the installer by accessing parameter L3. The range for this
parameter is 0 cycles to 100,000 cycles. The default is 10,000
cycles.

L4: Reset service reminder

Once servicing has been completed, the service notification
counter should be reset. This parameter can be reset by the
installer by accessing parameter L4. Once accessed, press the
RESET key to reset the service notification counter.

L5: Personality plug

After replacing a control board, the new control will require
the installer to verify the model in which it is installed. As soon
as the power is turned on, the screen will display “Wrong ID
Plg”. Look behind the control panel at the connector plugged
into X5 on the control board. Note the number written on the
connector. Access parameter L5. That number should appear
after the word “Setting:” on the bottom line. If this number
matches the number on the connector, press “Enter”.

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Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual

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;

• Check for leaks (water, gas, flue,
condensate)

• Examine venting system

• Check system water pressure/system
piping/expansion tank

• Check control settings

• Check igniters

• Check wiring and connections

• Check flue gas passageways

• Flame inspection (stable, uniform)

ANNUAL START-UP

• Inspect and clean the burners

• Check manifold gas pressures

Owner maintenance

(see the User’s Information Manual for instructions)

• Check appliance area

• Check pressure/temperature

Daily

Monthly

Periodically

gauge

• Check vent piping

• Check air piping

• Check relief valve

• Replace combustion air filter
Note: More frequent replacement may
be necessary in dirty environments.
Do not use pleated filters.

• Test low water cutoff (if used)

• Perform start-up checkout and
performance verification per the Startup
Section in the Installation and Operation
Manual.

If combustion or performance
indicate need:

• Clean heat exchanger with a stiff bristle
brush

• Remove and clean burners using
water. Dry before re-assembling.

• Clean the blower wheel with a brush and
vacuum. Do not let dirt from cleaning get
pulled into the blower.

Every

6 months

End

of season

months

• Reset button (low water cutoff)

• Check appliance piping (gas and

water) for leaks

• Operate relief valve

• Shut appliance down (unless

boiler used for domestic hot
water)

23

2 Maintenance

Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual

 WARNING

 WARNING

 WARNING

Follow the service and maintenance procedures given throughout this manual and in component literature
shipped with the appliance. Failure to perform the service and maintenance could result in damage to the
appliance or system. Failure to follow the directions in this manual and component literature could result in
severe personal injury, death, or substantial property damage.

The appliance should be inspected annually only by a qualified service technician. In addition, the maintenance
and care of the appliance designated in Table 2A and explained on the following pages must be performed to
assure maximum appliance efficiency and reliability. Failure to service and maintain the appliance and system
could result in equipment failure.

Electrical shock hazard – Turn off power to the appliance before any service operation on the appliance except as
noted otherwise in this instruction manual. Failure to turn off electrical power could result in electrical shock,
causing severe personal injury or death.

Address reported problems

1. Inspect any problems reported by the owner and correct
before proceeding.

Inspect appliance area

1. Verify that appliance area is free of any combustible
materials, gasoline and other flammable vapors and liquids.

Inspect appliance interior

1. Remove the outer access panels and inspect the interior of
the appliance.

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. Check this filter
every month and replace. The filter size on the 500,000 ­750,000 Btu/hr models is 12" x 12" x 1" and 16" x 16" x 1" on
the 990,000 - 2,070,000 Btu/hr models. You can find these
commercially available at any home center or HVAC supply
store. Do not use pleated filters.

Check water system

2. Vacuum any sediment from inside the appliance and
components. Remove any obstructions.

Check all piping for leaks

 WARNING

1. Inspect all water and gas piping and verify to be leak free.

2. Look for signs of leaking lines and correct any problems
found.

3. Check gas line using the procedure found in the Gas
Connections of the Installation and Operation Manual.

Eliminate all system or appliance leaks.
Continual fresh makeup water will reduce
appliance life. Minerals can build up in
sections, reducing heat transfer, overheating
heat exchanger, and causing heat exchanger
failure. Leaking water may also cause severe
property damage.

Flue vent system and air piping

1. Check for gastight seal at every connection, seam of air
piping, and vent piping periodically inspected by a qualified
service agency.

 WARNING

24

Venting system must be sealed gastight
to prevent flue gas spillage and carbon
monoxide emissions, which will result in
severe personal injury or death.

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 a minimum of 12 PSI).

3. Watch the system pressure as the boiler heats up (during
testing) to ensure pressure does not rise too high.
Excessive pressure rise indicates expansion tank sizing or
performance problem.

4. Inspect automatic air vents and air separators. Remove
air vent caps and briefly press push valve to flush vent.
Replace caps. Make sure vents do not leak. Replace any
leaking vents.

Check expansion tank (if provided)

1. Expansion tanks provide space for water to move in
and out as the heating system water expands due to
temperature increase or contracts as the water cools.
Tanks may be open, closed, diaphragm or bladder type.
See the Water Connections Section of the Installation and
Operation Manual for suggested best location of expansion
tanks and air eliminators.

Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual

2 Maintenance (continued)

Check relief valve

1. Inspect the relief valve and lift the lever to verify flow.
Before operating any relief valve, ensure that it is piped with
its discharge in a safe area to avoid severe scald potential.
Read the Water Connections Section of the Installation and
Operation Manual before proceeding further.

 WARNING

 WARNING

2. After following the above warning directions, if the relief
valve weeps or will not seat properly, replace the relief valve.
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.

Safety relief valves should be re-inspected
AT LEAST ONCE EVERY THREE YEARS,
by a licensed plumbing contractor or
authorized inspection agency, to ensure
that the product has not been affected by
corrosive water conditions and to ensure
that the valve and discharge line have not
been altered or tampered with illegally.
Certain naturally occurring conditions may
corrode the valve or its components over
time, rendering the valve inoperative. Such
conditions are not detectable unless the
valve and its components are physically
removed and inspected. This inspection
must only be conducted by a plumbing
contractor or authorized inspection agency
– not by the owner. Failure to re-inspect the
boiler relief valve as directed could result in
unsafe pressure buildup, which can result in
severe personal injury, death, or substantial
property damage.

Following installation, the valve lever must
be operated AT LEAST ONCE A YEAR to
ensure that waterways are clear. Certain
naturally occurring mineral deposits may
adhere to the valve, rendering it inoperative.
When manually operating the lever, water
will discharge and precautions must be taken
to avoid contact with hot water and to avoid
water damage. Before operating lever, check
to see that a discharge line is connected to
this valve directing the flow of hot water
from the valve to a proper place of disposal.
Otherwise severe personal injury may result.
If no water flows, valve is inoperative. Shut
down the appliance until a new relief valve
has been installed.

Inspect/replace hot surface igniter

This unit uses a proven hot surface ignition module and a
hot surface igniter. The hot surface ignition module is not
repairable. Any modification or repairs will invalidate the
warranty.

 WARNING

A faulty hot surface igniter or ignition module must be replaced
with an identical part. A specification igniter and ignition
module for this specific unit is available from your local
distributor. Do not use general purpose field replacement

ignition modules or igniters.

Do not attempt to repair a faulty hot
surface igniter or ignition module. Any
modification or repairs may create
hazardous conditions that result in property
damage, personal injury, fire, explosion
and/or toxic gases.

Inspect/replace hot surface igniters

1. Turn off main electrical power to the appliance.

2. Turn off main manual gas shutoff to the appliance.

3. Remove lower front door to gain access to the hot surface
igniter.

4. Locate the hot surface igniter. Disconnect the two power
leads to the hot surface igniter.

5. Loosen and remove the two screws used to attach the
igniter.

6. Remove the igniter from the combustion chamber door.
Use care, do not hit or break the silicon carbide igniter. Do
not contaminate the igniter by handling with oily or dirty
hands.

7. Check the replacement igniter for cracks or damage before
installing.

8. Ensure that the fiber gasket used to seal the base of the
igniter to the combustion chamber door is reinstalled to seal
the base of the replacement igniter.

9. Carefully insert the igniter into the opening of the
combustion chamber door and re-attach the two screws
removed in Step 5. Over-tightening may break the ceramic
mounting flange.

10. Ensure that the igniter gasket is properly installed and seals
the point of contact between the igniter and the combustion
chamber door.

11. Reconnect the power leads to the igniter.

12. Replace the lower front door.

13. Turn on main gas supply and main power.

14. Test fire the appliance to ensure proper operation.

25

2 Maintenance

Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual

Check all wiring

1. Inspect all wiring, making sure wires are in good condition
and securely attached.

Check control settings

1. Set the SMART SYSTEM control module display to
Parameter Mode and check all settings. See Section 1 of this
manual. Adjust settings if necessary. See Section 1 of this
manual for adjustment procedures.

2. Check settings of external limit controls (if any) and adjust
if necessary.

Perform start-up and checks

1. Start appliance and perform checks and tests specified in
Start-up Section of the Installation and Operation Manual.

2. Verify cold fill pressure is correct and that operating
pressure does not go too high.

Check burner flame

Visually check main burner flames at each start-up after long
shutdown periods or at least every six months. The burner
viewports are located on either end of the appliance.

 WARNING

Figure 2-1_Flame Pattern Illustration

NORMAL

YELLOW FLAME

Normal Flame: A normal flame at 100% of burner input is
blue, with slight yellow tips, a well defined flame and no flame
lifting.

Yellow Tip: Yellow tipping can be caused by blockage or partial
obstruction of air flow to the burner.

The area around the burner viewport is hot
and direct contact could result in burns.

YELLOW TIP

FLAME LIFT

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. The following cleaning procedure must only
be performed by a qualified serviceman or installer. Proper
service is required to maintain safe operation. Properly installed
and adjusted units seldom need flue cleaning.

NOTICE

 CAUTION

All gaskets/sealants on disassembled
components or jacket panels must be replaced
with new gaskets/sealants on reassembly.
Gasket and sealant kits are available from
your distributor.

When a Category IV vent system is
disconnected for any reason, the flue must
be reassembled and resealed according to the
vent manufacturer’s instructions.

Inspect and clean burner

The burner should be removed for inspection and cleaned
on an annual basis. An appliance installed in a dust or dirt
contaminated environment may require cleaning of the burner
on a 3 to 6 month schedule or more often, based on severity of
the contamination. The fan assisted combustion process may
force airborne dust and dirt contaminants, contained in the
combustion air, into the burner. With sustained operation,
non-combustible contaminants may reduce burner port area,
reduce burner input or cause non-warrantable damage to the
burner.

Use extreme care when operating an appliance for temporary
heat during new construction. Airborne contaminants such
as dust, dirt, concrete dust or drywall dust can be drawn into
the burner with the combustion air and block the burner port
area. An external combustion air filter is provided with the
appliance. This filter helps ensure clean air is used for the
combustion process. Check this filter every month and replace
when it becomes dirty. The burner of an appliance used for
temporary heat without a combustion air filter installed will
probably require a thorough cleaning before the unit is placed
into normal service.

Yellow Flames: Yellow flames can be caused by blockage of
primary air flow to the burner or excessive gas input. This
condition MUST be corrected immediately.

Lifting Flames: Lifting flames can be caused by over firing the
burner, excessive primary air or high draft.

If improper flame is observed, examine the venting system,
ensure proper gas supply and adequate supply of combustion
and ventilation air.

26

Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual

2 Maintenance (continued)

Access to the burner will require the following steps:

1. Turn off main electrical power to the appliance.

2. Turn off main manual gas shutoff to the appliance.

3. Remove the lower outer front access door.

4. Disconnect the manifold(s) from the gas train using the
union(s) just below each gas valve.

5. Disconnect the wiring to the hot surface igniter(s) and
ground.

6. Disconnect burner pressure line at burner.

7. Remove the screws from the manifold mounting bracket(s)
and remove the manifold(s).

8. Remove the screws from the burner mounting flanges and
slide the burner(s) out toward the front of the unit. Use
caution to prevent damage to the burners, refractory, hot
surface igniter, and wiring.

9. Remove soot from the burners with a stiff bristle brush.
Dirt may be removed from the burner ports by rinsing the
burner thoroughly with water. Drain and dry burners
before re-installing. Damaged burners must be replaced.

Checking combustion air pressure

The combustion air fans are factory pre-set and should not
require adjustment in most cases. Follow the steps in the
Checking / Adjusting Combustion Air Pressure Section to adjust
the fan if a continuous Low Air status code occurs.

NOTICE

Check for proper installation and draft in the venting system
prior to any adjustments. Correct as needed.

Figure 2-2_Adjusting air shutter - 399,999 - 750,000 Btu/
hr Models

LESS AIR

On the 399,999 - 750,000 Btu/hr models,
the air shutter is adjusted to the side of the
fan as depicted in FIG. 2-2. On the 990,000

- 2,070,000 Btu/hr models, the air shutter is
adjusted by sliding the arm located on the
front of the air box as depicted in FIG. 2-3.

10. Reassemble in reverse order.

NOTICE

When installed in a dusty and dirty location,
the burners may require cleaning on a 3 to 6
month schedule or as needed, based on the
severity of contamination. Contaminants
can be drawn in with the combustion air.
Non-combustible particulate matter such as
dust, dirt, concrete dust, or drywall dust can
bloc burner ports and cause non-warrantable
failure. The standard inlet air filter will help
eliminate dust and dirt from entering the
unit.

NOTICE

While burners are removed, check the heat
exchanger surface for sooting. If present, the
heat exchanger must be cleaned. Reference
the Heat Exchanger Cleaning procedures in
this manual.

MORE AIR

AIR SHUTTER

Figure 2-3_Adjusting air shutter - 990,000 - 2,070,000
Btu/hr Models

MORE AIR

LESS AIR

AIR SHUTTER
ADJUSTING BRACKET

27

2 Maintenance

Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual

Adjusting combustion air pressure

The following is a recommended method for setting the
combustion air pressure. The following pressure settings are
for installations up to 4000 feet altitude. Contact the factory for
high altitude air pressure settings.

Upon removal of the upper front doors, locate the capped tee
in the pressure tubing that connects between the inner top and
the gas valves. Remove this cap and connect a hose from the tee
to a manometer.

For 399,999 - 750,000 Btu/hr models (reference FIG. 2-2)

1. The combustion air chamber pressure for these models is
typically 1.2 - 1.3 inches water column when the fan is at
high speed.

2. If adjustment is necessary, slightly loosen the nuts
connecting the fan to the inner top.

3. Adjust the air shutter located underneath the fan assembly
to obtain the desired chamber pressure. Slide the shutter
inward to decrease the chamber pressure or outward to
increase the chamber pressure.

For 990,000 - 2,070,000 Btu/hr models (reference
FIG. 2-3)

1. The combustion air chamber pressure for these models is
typically 1.2 - 1.3 inches water column when the fan is at
high speed.

2. If adjustment is necessary, slightly loosen the nut
located on the air shutter arm.

3. Adjust the air shutter arm to obtain the desired chamber
pressure. Slide the arm inward to decrease the chamber
pressure or outward to increase the chamber pressure.

All models

4. Once the adjustment procedure is complete, tighten all
connections, disconnect the manometer, and replace the
cap at the tee.

5. Check all connections and test fire the unit.

6. Replace all panels.

Checking manifold gas pressure

The gas regulator on the combination gas valve is adjustable to
supply the proper manifold pressure for normal operation. The
gas valves are factory pre-set and should not need adjusting in
most cases. Gas manifold pressures are listed in Table 2B.

Checking manifold gas pressure

1. Turn the appliance power switch to the “OFF” position.

2. Remove the upper outer access panels.

3. Remove the 1/8" hex plug from the downstream side of
the gas valve (see FIG. 2-4). Install a fitting in the tap
and connect a hose from the tap to a manometer.

4. Connect a hose from the tee used to measure the
combustion air pressure to the other side of the
manometer.

5. Turn the appliance power switch to the “ON” position.

6. With the unit at high fire, check and record the
manifold pressure of the valve. The manifold pressure
will be the sum of the two pressure readings (reference
Table 2B).

7. Repeat this process with each gas valve.

 WARNING

If you must adjust the gas valve regulator pressure,
follow the steps below:

1. Remove the cap covering the manifold pressure
adjustment screw (see FIG. 2-4). Note: Once the cap
is removed, the pressure shown on the manometer will
change and the unit may turn off.

2. Make a slight adjustment to the manifold pressure
adjustment screw. Turning the screw clockwise
increases manifold pressure and counterclockwise
decreases manifold pressure.

3. Replace the cap and check the manifold pressure.
Note: Allow the unit to re-light if necessary.

4. Repeat the steps above to match the manifold pressures
from Table 2B.

5. Once the adjustment procedure is complete, turn off
the appliance, disconnect the manometer, replace and
tighten all connections, and replace all panels.

6. Turn on the appliance and test fire the unit.

7. Repeat this process with each gas valve.

Overfire and underfire hazards!
Possible fire, explosion, overheating,
and component failure. Do not attempt
to adjust firing rate of the appliance.
The firing rate must be adjusted only by
factory trained personnel.

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.

28

Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual

2 Maintenance (continued)

Figure 2-4_Measuring manifold gas pressure

MANIFOLD
PRESSURE

PRESSURE
REGULATOR
ADJUSTMENT
(UNDER CAP
SCREW)

INLET

CHAMBER
PRESSURE

TEE

OUTLET

MANOMETER

GAS
VALVE
CONTROL
KNOB

TO BARBED
FITTING

TABLE 2B

Net Manifold Pressure

Regulator Pressure Less

Front Chamber Pressure

MODEL Nat. Gas LP

402 - 752 1.8'' w.c. 4.6’’ w.c.

992 - 2072 1.2'' w.c. 4.6’’ w.c.

29

Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual

2 Maintenance

Inspect and clean the heat exchanger

1. Turn off the main electrical power to the appliance.

2. Turn off the main manual gas shutoff to the appliance.

3. Remove the lower outer fron access door.

4. Disconnect the manifold(s) from the gas train using the
union(s) just below each gas valve.

5. Disconnect wiring to the hot surface igniter(s) and ground.

6. Disconnect burner pressure line at burner.

7. Remove the screws from the manifold mounting bracket(s)
and remove the manifold(s).

8. Remove the screws from the burner mounting flanges and
slide the burner(s) out toward the front of the unit. Use
caution to prevent damage to the burners, refractory, hot
surface igniter, and wiring.

9. Remove the inner jacket panel mounting screws and slide
the panel assembly out toward the front of the appliance.
Use caution to prevent damage to the refractory and hot
surface igniter.

10. Check “V” baffles along the front and back edges of the heat
exchanger (FIG. 2-5). Remove and clean if necessary.

11. Remove soot from the heat exchanger with a stiff bristle
brush. Use a vacuum to remove loose soot from the
surfaces and inner chamber.

12. If additional cleaning is required, the heat exchanger
can be removed by disconnecting all water piping to the
heat exchanger, removing the screws holding the heat
exchanger to the inner left side panel, and sliding the heat
exchanger towards the front of the appliance. Once the heat
exchanger is removed from the appliance, a garden hose can
be used to wash the tubes to ensure that all soot is removed
from the heat exchanger surfaces.

NOTICE

Do not wet the refractory located on the
inside of the combustion chamber.

HEAT

EXCHANGER

Figure 2-5_Location of the Heat Exchanger Inside Jacket

Review with owner

1. Review the User’s Information Manual with the owner.

2. Emphasize the need to perform the maintenance schedule
specified in the User’s Information Manual (and in this
manual as well).

3. Remind the owner of the need to call a licensed contractor
should the appliance or system exhibit any unusual behavior.

4. Remind the owner to follow the proper shutdown procedure
and to schedule an annual start-up at the beginning of the
next heating season.

Oiled bearing circulators

Inspect the pump every six (6) months and oil as necessary. Use
SAE 30 non-detergent oil or lubricant specified by the pump
manufacturer.

13. Ensure that all burner ports are cleaned to remove any soot
(reference this section).

14. Carefully reinstall the heat exchanger, “V” baffles, and
frame runners if removed from the appliance.

NOTICE

15. Carefully reinstall inner jacket panels, burners, manifolds,
wires and hoses. Use new gasket material to ensure a
proper air seal.

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.

Make sure the frame runners seal securely
where they contact the front and rear
compartment refractory.

30

3 Troubleshooting

Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual

 WARNING

Label all wires prior to disconnection when
servicing controls. Wiring errors can cause
improper and dangerous operation. Always
disconnect power to the appliance before
servicing. Failure to comply could result in
severe personal injury, death, or substantial
property damage.

 WARNING

Never jumper (bypass) any device except
for momentary testing as outlined in the
Troubleshooting chart. Severe personal
injury, death, or substantial property damage
can result.

Before troubleshooting:

1. Have the following items:
a. Voltmeter that can check 120 VAC, 24 VAC, and
12 VDC.
b. Continuity checker.
c. Contact thermometer.

2. Check for 120 VAC (minimum 102 VAC to maximum

132 VAC) to appliance.

3. Make sure thermostat is calling for heat and contacts

(including appropriate zone controls) are closed. Check for
24 VAC between thermostat wire nuts and ground.

4. Make sure all external limit controls are installed and

operating.

Check control module fuses

NOTICE

1. Turn OFF the power to the appliance at the external line
switch.

2. Remove front access cover.

3. Inspect fuses F2, F4, F5, and F6, see FIG. 3-1 below.

Figure 3-1_Control Module Fuses

F4

5 AMPS

F2

3.15 AMPS

ALWAYS check control module fuses before
replacing control module or any major
components (blower, etc.). If one of these
fuses is blown, it can prevent the control
module or other components from operating.

F6
5 AMPS

F5
5 AMPS

Check the following:

1. Wire connectors to control module are securely plugged in

at the module and originating control.

2. Gas pressures:

Refer to the Gas Connections Section of the Installation and
Operation Manual for detailed information concerning the
gas supply.

4. The appliance is shipped with four (4) spare fuses in a plastic
bag attached to the control panel.

5. If necessary, replace open fuse (F2 is 3.15 amps and F4, F5,
and F6 are 5 amps).

Note: Fuses F2 - F6 are all slow blow fuses.

 WARNING

Do not jumper fuse or replace with any fuse
except as specified. Failure to comply could
result in severe personal injury, death, or
substantial property damage.

6. Install front access cover after fuse inspection.

7. Restore power to the appliance at the external line switch
and verify boiler/water heater operation (Start-up Section
in the Installation and Operation Manual) after completing
boiler/water heater service.

31

Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual

3 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 Display

- No 120 VAC supplied to unit.

- Bad wiring connection.

ON position.

• Check 120 VAC through the ON/OFF switch. No
voltage through switch, replace switch.

• Check wiring harness connection between the display
board and the main control board. Connect the harness
at both points.

No Burner

Operation

Unit Does Not

Modulate to

100%

- Blown fuse.

- Bad display board. • Replace board.

- Bad main control board. • Replace main control board.

- Main control board temperature set point
satisfied.

- Remote thermostat satisfied.

- Outside air temperature above Warm
Weather Shutdown (WWSD) set point for
main control board.

- Unit locked out on fault.

- Ramp delay active.

- Boiler controlled by BMS.

- Outlet temperature too high.

- Delta T too high.

• Replace fuse F6 on the main control board, see
FIG. 3-1 on page 31 of this manual.

• Review temperature setting.

• Review remote thermostat setting.

• Check location of outside air sensor. Check
resistance of outdoor air sensor and compare to Table
3D on page 33 of this manual.

• Consult display for specific fault. Refer to fault
descriptions on pages 35 - 42 of this manual for
corrective actions.

• Check ramp delay parameter settings. Optional PC
software required.

• Turn ramp delay feature off. See page 18 of this
manual for instructions on how to turn this feature off.

• Check BMS parameter settings. Optional PC
software required.

32

Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual

3 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. If the resistance of the sensor does not closely match its corresponding
table, replace the sensor.

Table 3B Inlet/Outlet/System/Tank Sensor Resistance vs. Temperature

S1a Inlet/Outlet/System/Tank

(Wire Color - R and W)

Temperature Resistance Temperature Resistance Temperature Resistance Temperature Resistance

50 19,553 158 2,004 50 40,030 158 3,478

68 12,690 176 1,464 68 25,030 176 2,492

86 8,406 194 1,084 86 16,090 194 1,816
104 5,715 212 816 104 10,610 212 1,344
122 3,958 122 7,166
140 2,786 140 4,943

Table 3C Outdoor Air Sensor Resistance vs. Temperature

Temperature Resistance Temperature Resistance

-50 490,813 20 46,218

-40 336,606 30 34,558

-30 234,196 40 26,099

-20 165,180 50 19,900

-10 118,018 60 15,311

S1b Outlet Only

(Wire Color - Bk and G)

0 85,362 70 11,883

10 62,465 80 9,299

33

Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual

3 Troubleshooting

Table 3D Troubleshooting Chart - Noisy System

FAULT CAUSE CORRECTIVE ACTION

- Gas supply problem. • Ref er to th e Gas Connections Section of the
Installation and Operation Manual for detailed
information concerning the gas supply.

- Gas/air mixture problem. • Refer to the Checking Manifold Gas Pressure and
Combustion Analysis Procedure on pages 27 and 28 of
this manual for the proper settings. Verify
that the vent/air intake lengths do not exceed the
maximum listed in the Venting section of the
Installation and Operation Manual.

- Dirty/damaged burner. • Refer to pages 26 and 27 in this manual for the burner

Noisy

Operation

removal and inspection procedure. Clean or replace the
burner as necessary.

No Pump

Operation -

Boiler Pump

System Pump

or

DHW Pump

- Low water flow through the heat exchanger. • Refer to the Water Connections Section of the
Installation and Operation Manual for
minimum flow rates. Verify that the appliance is piped in
a primary/secondary fashion and that the appliance and
system pump are running on a call for heat.

- Air in the piping system. • Properly purge all air from the piping system.

- Low system water pressure. • Verify system pressure is a minimum of 12 PSI.

- Faulty pump relay.

- Faulty pump.

- Internal fault on control board.

- System pressure exceeds relief valve

setting.

• Replace relay.

• Replace pump.

• Check fuse F5.

• Replace main control board.
Note: Make sure the boiler pump horse power (hp) does

not exceed 1 hp.

• Lower the system pressure below the rating of
the supplied relief valve or replace the standard relief
valve with a higher rated valve up to the maximum
pressure of the heat exchanger.

Relief Valve

Opening

34

- Improperly sized expansion tank. • Install properly sized expansion tank.

- Outlet water temperature in excess of 210°.

• Check set point of temperature control.

• Check temperature rise across heat exchanger. Refer to
the temperature rise chart in the Water
Connections Section of the Installation and Operation
Manual.

Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual

3 Troubleshooting (continued)

Table 3E Troubleshooting Chart - Fault Messages Displayed on Operator Interface

FAULT DESCRIPTION CORRECTIVE ACTION

Gas Pressure SW

(Will require a manual

reset once the condition

has been corrected.)

Flow Switch/

LWCO

(Lockout will reset
automatically after

5 minutes or may be

reset immediately once

condition has been

corrected. Press the

RESET button on the

SMART SYSTEM display

to reset.)

Flame Sequence

(Will require a manual

reset once the condition
has been corrected. Press
the RESET button on the

SMART SYSTEM

to reset.)

display

- Either the optional manual reset low gas
pressure switch or the optional manual reset
high gas pressure switch tripped.

- Models 992 - 2072 (natural gas) - Automatic
Reset Low Gas is open.

Either the flow switch or the optional low
water cutoff is not making.

The flame detector circuit is seeing a flame
signal while the gas valve is de-energized.

• Reset the pressure switches.

• Measure the supply gas pressure to determine
cause of failure. Refer to the Gas Connections
Section of the Installation and Operation Manual for
detailed information concerning the gas supply.

• Correct the supply gas pressure if necessary.

• Check pump operation on a call for heat.

• Check for closed valves or obstructions in the
water piping.

• Verify system is full of water and all air has been
purged from the system.

• Check supply voltage for proper polarity.

• Check that the gas valve is closed.

• Check external wiring for voltage feedback.

• Check the internal wiring for bad connections.

• Replace main control board.

Anti-cycling

The main control board has received a call
for heat too quickly after the previous call for
heat has ended.

• The control board will release the call for heat after
a set time period.

• The control board will release the call for heat if the
outlet temperature drops too quickly.

35

Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual

3 Troubleshooting

Table 3E (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Operator Interface

FAULT DESCRIPTION CORRECTIVE ACTION

No Flame Ign

(Will require a manual

reset. Press the RESET

button on the SMART

SYSTEM

display to reset.)

The unit has failed to prove burner flame
upon ignition.

• Inspect igniter and associated wiring for damage and
connection. Reference page 25 of this manual for
removal and cleaning procedure. Replace if
necessary.

• Check for proper electrical grounding of unit.

• Check incoming supply gas pressure. Refer to the
Gas Connections Section in the Installation and
Operation Manual for detailed information concerning
the gas supply.

• Verify that the tube from the gas valve to the combustion
air chamber is connected and is not damaged.

• Verify that the vent/air intake pipes are correctly
installed and that there are no obstructions.

• Inspect the burners. Reference pages 26 and 27
of this manual for removal and cleaning procedures.
Replace if necessary.

• Refer to the Checking Manifold Gas Pressure and
Combustion Analysis Procedure on pages 27 and 28
of this manual for the proper settings.

• Check for 24 VAC to the gas valve during the ignition
attempt. If no voltage is present, check the wiring
between the gas valve and the main control board.

HSI Current Low

(Will require a manual

reset once the condition

has been corrected. Press

the RESET button on the
SMART SYSTEM

to reset.)

display

Flame CKT

Error

36

Amp draw of the hot surface igniter did not
meet the minimum requirement of 2.6 amps.

The main control board has detected an
internal fault.

• Replace the wiring or the main control board as
necessary.

• Measure the amp draw of the hot surface igniter during
the trial for ignition stage. If less than 2.6 amps
replace the hot surface igniter.

• If more than 2.6 amps replace the control module.

• Replace the main control board.

Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual

3 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. Reference page 25 of this manual for
removal and cleaning procedure. Replace if
necessary.

• Check for proper electrical grounding of unit.

• Check incoming supply gas pressure. Refer to the
Gas Connections Section of the Installation and

No Flame

Running

(Will require a manual
reset once the condition

has been corrected. Press
the RESET button on the

SMART SYSTEM

to reset.)

display

Operation Manual for detailed information concerning
the gas supply.

• Verify that the tube from the gas valve to the
combustion air chamber is connected and is not
damaged.

• Verify that the vent/air intake pipes are installed
correctly and there are no obstructions.

Auto Reset

High Limit

The outlet water temperature has exceeded the
setting of the automatic reset high limit.

• Refer to the Checking Manifold Gas Pressure and
Combustion Analysis Procedure on pages 27 and 28
of this manual for the proper settings.

• Inspect the burners. Reference pages 26 and 27
of this manual for removal and cleaning procedures.
Replace if necessary.

• Replace the main control board.

• Verify that the system is full of water and that all air
has been properly purged from the system.

• Verify that the appliance is piped properly into the
heating system. Refer to the Water Connections
Section of the Installation and Operation Manual for
the proper piping methods for the Copper-fin.

• Check 120 VAC to boiler pump motor on a call for
heat. If voltage is not present, check wiring back
to the main control board. Replace the main
control board if necessary.

• If 120 VAC is present on a call for heat and the
pump is not operating, replace the pump.

• If the system pump is a variable speed pump,
ensure that the system flow is not less than the
boiler flow.

• Check temperature setting of the main control
board.

• Check resistance of water sensors and compare to
Table 3B on page 33 of this manual. Replace
sensor if necessary.

• Replace outlet sensor.

37

Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual

3 Troubleshooting

Table 3E (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Operator Interface

FAULT DESCRIPTION CORRECTIVE ACTION

Manual Reset

High Limit

(Will require a manual

reset once condition has

been corrected. Press
the RESET button on
the SMART SYSTEM

display to reset.)

Inlet Low

The outlet water temperature has exceeded
the setting of the adjustable high limit.

The inlet water temperature did not exceed
130° within 15 minutes of ignition.

• 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.

• Verify that the appliance is piped properly into the
system. Refer to the Water Connections Section of
the Installation and Operation Manual for
proper piping methods for the Copper-fin.

• Check 120 VAC to the pump motor on a call for heat.
If voltage is not present, check wiring leading to the
main control board. Replace the main control board if
necessary.

• If 120 VAC is present on a call for heat and the pump
is not operating, replace the pump.

• If the system pump is a variable speed pump, ensure
the system flow is not less than the boiler flow.

• Check temperature setting of the main control board.

• Check resistance of water sensors and compare to
the tables on page 33 of this manual. Replace the
sensor if necessary.

• Replace outlet sensor or high limit.

• Raise temperature set point above 130°.

• Install a 3-way valve or LTV valve per the piping
diagram in the Water Connections Section of the
Installation and Operation Manual.

Sensor Open

(Will require a manual

reset once the condition
has been corrected. Press
the RESET button on the

SMART SYSTEM

to reset.)

display

Sensor Shorted

(Will require a manual

reset once the condition
has been corrected. Press
the RESET button on the

SMART SYSTEM

to reset.)

display

38

Either the inlet water, outlet water, system
supply, system return, or outdoor temperature
sensor has been disconnected.

Either the inlet water, outlet water, system
supply, system return, or outdoor temperature
sensor has been shorted.

• Replace the inlet sensor.

• Replace the main control board.

• Check the sensors and their associated wiring.
Repair or replace the sensor or wiring if damaged.

• Measure the resistance of the sensors and compare
the resistance to the tables on page 33 of this
manual.

• Replace the sensor if necessary.

• Check the sensors and their associated wiring.
Repair or replace the sensor or wiring if damaged.

• Measure the resistance of the sensors and compare
the resistance to the tables on page 33 of this
manual.

• Replace the sensor if necessary.

Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual

3 Troubleshooting (continued)

Table 3E (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Operator Interface

FAULT DESCRIPTION CORRECTIVE ACTION

Louver Proving

(Lockout will reset
automatically after

5 minutes or may be

reset immediately once

condition has been

corrected. Press the

RESET button on the

SMART SYSTEM display

to reset.)

An optional remote proving switch is not
making.

• Check function of remote devices.

• Check for loose or misplaced jumper if
proving switch is not installed.

Tank Open

APS Open

(Lockout will reset

automatically after 5

minutes or may be

reset immediately once

condition has been

corrected. Press the

RESET button on the

SMART SYSTEM display

to reset.)

APS Closed

(Lockout will reset

automatically after 5

minutes or may be

reset immediately once

condition has been

corrected. Press the

RESET button on the

SMART SYSTEM display

to reset.)

Sensors equipped with an internal limit (such
as the Lochinvar Squire® Indirect Tank), the
limit has opened due to temperature (195°F)
or the sensor has become disconnected.

The air pressure switch did not make within
1 minute after the combustion air blower has
been energized.

The SMART SYSTEM control sensed that
the air pressure switch was closed before the
combustion air blower was energized.

• Check the tank temperature.

• Repair or replace the sensor wiring if damaged.

• Replace the sensor if necessary.

• Check air filter. Clean or replace as necessary.

• Vent/air intake lengths exceed the maximum allowed
lengths.

• Check for blockage or obstruction in vent/air inlet pipe
or at terminations.

• Verify combustion air blower is operating. Replace if
necessary.

• Check for jumper on air pressure switch.

• Check for an unusually high negative draft in the vent
stack.

Wrong ID Plug

Control module ID plug does not match
parameter L5.

• Verify that ID plug is connected properly to connector
X5 on the control module.

• Verify that the wiring in the ID plug is not cut or
damaged and that the wiring connectors are seated
properly in the plug.

• Verify that the number on the ID plug matches the
number in parameter L5. If not, replace the control
module.

• When replacing control modules, verify that the
number in parameter L5 matches the number on the
ID plug (reference page 22 of this manual). If
so, press the ENTER button on the SMART
SYSTEM display. If not, replace the control module.

39

Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual

3 Troubleshooting

Table 3E (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Operator Interface

FAULT DESCRIPTION CORRECTIVE ACTION

Temp O/Shoot

(Lockout will reset

automatically after 5

minutes or may be

reset immediately once

condition has been

corrected. Press the

RESET button on the

SMART SYSTEM display

to reset.)

The temperature rise across the heat
exchanger has exceeded the set parameters
for the appliance.

Outlet water temperature has exceeded the
maximum outlet water temperature.

• Verify that the system is full of water and that all air
has been properly purged from the system.

• Verify that the appliance is piped properly into the
heating system. Refer to the Water Connections
Section of the Installation and Operation Manual for the
proper piping methods.

• Check for 120 VAC to the pump motor on a call
for heat. If voltage is not present, check the wiring
leading to the main control board. Replace the main
control board if necessary.

• If 120 VAC is present on a call for heat and the
pump is not operating, replace the pump.

• Verify that the system is full of water and that all air
has been properly purged from the system.

• Verify that the appliance is piped properly into the
system. Refer to the Water Connections Section of
the Installation and Operation Manual for the proper
piping methods.

• Check 120 VAC to the pump motor on a call for heat.
If voltage is not present, check wiring leading to the
main control board. Replace the main control board
if necessary.

Rem Ctrl Flt

40

• If 120 VAC is present on a call for heat and the
pump
is not operating, replace pump.

• Replace the main control board.

External control is cycling too often. • Check set point of the external control.

• Check the wiring between the external control and
the unit.

• Replace the control.

Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual

3 Troubleshooting (continued)

Table 3E (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Operator Interface

FAULT DESCRIPTION CORRECTIVE ACTION

Parameters

Progr

(Will require a manual

reset once the condition

has been corrected. Press

the RESET button on the
SMART SYSTEM

to reset.)

display

Service Blk

After downloading parameters from a laptop,
the main control board must be reset.

While the unit is in Service Mode, the outlet
temperature has exceeded 185°F (85°C).

• Press the ENTER/RESET button on the Smart
System display panel.

• Establish a heating load to remove heat from the
system.

• Verify that the system is full of water and that all air
has been properly purged from the system.

• Verify that the appliance is piped properly into the
system. Refer to the Water Connections Section of
the Installation and Operation Manual for the proper
piping methods.

• Check 120 VAC to the pump motor on a call for
heat. If voltage is not present, check the wiring
leading to the main control board. Replace the main
control board if necessary.

Low Voltage

120 VAC input to the main control board has
dropped below 100 VAC.

• If 120 VAC is present on a call for heat and the
pump is not operating, replace the pump.

• Check 120 VAC supply to the transformer.

• Check wiring connections at the low voltage terminal
strip.

• Check the wire size/length to remote devices.

• Replace the main control board.

41

Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual

3 Troubleshooting

Table 3E (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Operator Interface

FAULT DESCRIPTION CORRECTIVE ACTION

Watch Dog Error

Write EEProm

Program EEProm

CRC Parameters

No Error Stored

The main control board has detected an
internal fault.

The main control board has detected an
internal fault.

The main control board has detected an
internal fault.

The main control board has detected an
internal fault.

The main control board has detected an
internal fault.

• Cycle main power.

• Replace the main control board.

• Cycle main power.

• Replace the main control board.

• Cycle main power.

• Replace the main control board.

• Cycle main power.

• Replace the main control board.

• Restore default parameters using the PC program.

• Press RESET.

• Cycle main power.

• Replace the main control board.

42

NOTES

43

Revision Notes: Revision A (ECO #C08226) initial release.

Revision B (ECO #C08896) reflects the update of Parameter
Table 1-D on pages 13 - 14 and Parameter information
on pages 17 and 19. Table 3B on page 33 for sensor
information was also updated.

C(F,H,P)X-SER Rev B

9/11