Lochinvar CPL0652 Service Manual
CPX-SER Rev D
Copper-fin II/IIE
Pool Heater
Service Manual
Models: 502 - 2072
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
Display Panel Menu Access ............................................ 10
Display Panel Parameter Access ..................................... 11
Parameter Table............................................................... 12
Viewable and Changeable Control Parameters .......... 13-16
2. MAINTENANCE
Maintenance and Annual Startup ................................ 17-24
3. TROUBLESHOOTING
Before Troubleshooting .................................................... 25
Check Control Module Fuses .......................................... 25
Table 3A - Troubleshooting Chart - No Display ............... 26
Checking Temperature Sensors ...................................... 27
Table 3C - Troubleshooting Chart - Noisy System .......... 28
Table 3D - Troubleshooting Chart - Fault Messages .. 29-35
Revision Notes .................................................. Back Cover
Hazard definitions
The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels
or to important information concerning the life of the product.
DANGER
WARNING
CAUTION
CAUTION
NOTICE
DANGER indicates an imminently hazardous situation which, if not avoided, will result 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 Pool Heater 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 –
• 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 Pool Heater 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 -- Pool 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 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: Anti-cycling
• F: Control Modes
• G: Cascade
• H: Pumps
• I: 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 Pool Heater Service Manual
• 2-Line / 16 character LCD display
• Backlit LCD
• 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 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
POOL SUPPLY
SENSOR
POOL SENSOR
CASCADE
Copper-fin II/IIE Pool Heater Service Manual
SENSOR
CONNECTION
LOW
VOLTAGE
CONNECTION
BOARD
BOARD
ENABLE
LOUVER PROVING SWITCH
(FIELD PROVIDED)
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)
MODBUS
BOARD
(OPTIONAL)
SMART
SYSTEM
CONTROL
BOARD
6
1 Service (continued)
Control outputs
Copper-fin II/IIE Pool Heater Service Manual
MODBUS
BOARD
(OPTIONAL)
SMART
SYSTEM
CONTROL
BOARD
LOW
VOLTAGE
CONNECTION
BOARD
MODBUS
0-10V
FIRING RATE
CASCADE
THREE WAY VALVE
LOUVER RELAY
BUILDING
MANAGEMENT
SYSTEM
RUN TIME CONTACTS
ALARM CONTACTS
ALARM
(OPTIONAL)
HEATER PUMP
INDICATES CONNECTIONS MADE TO THE LINE VOLTAGE TERM
INAL 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 Pool Heater 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 and the firing rate of the appliance.
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 the heater
pump 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 is based on heater outlet
water temperature, pool supply temperature and pool return
temperature.
Sequence of operation
Table 1A shows control module normal sequences of operation
for pool heater operation.
Access modes
User
The user can adjust pool set point by entering the USER code
(0704). The user can also change temperature units and time
and date. In user mode, the following parameters can be viewed
but not changed: 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 Pool Heater Service Manual
1 Service (continued)
Sequence of operation
Table 1A_Sequence of Operation - Pool Heating
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 unit pump. 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 prepurge, the blower slows down and the hot surface
igniter (HSI) is energized.
5. Once the HSI is hot, the trial for ignition begins with the
opening of the gas valve.
6. If the SMART SYSTEM control does not sense flame, then
it will lock out.
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)
HTR: POSTPURGE, PREPURGE
OUT: 123.9F(129)
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.
8. Once the call for heat is satisfied, the control will turn off
the burners. The blower will remain on for the
postpurge cycle. The unit pump will continue to run for its
pump delay time, then turn off.
9. Unit pump off.
HTR: RUN STG: 1
OUT: 124.8F(129)
HTR: POSTPURGE
OUT: 127.4F(129)
HTR: Standby
OUT: 122.9F(129)
9
Copper-fin II/IIE Pool Heater Service Manual
1 Service
Display panel menu access
Table 1B_Use this procedure to access menus from the display panel
10
Copper-fin II/IIE Pool Heater Service Manual
1 Service (continued)
Display panel parameter access
Table 1C_This is a typical example of accessing a parameter, shown for parameter H1, PH pump delay
Cascade
11
Loading...