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

Copper-fin II/IIE Pool Heater Service Manual

1 Service

Parameter table

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

Menu

Sub

Item

A

GENERAL

B

SETTINGS

TEMPERATURE

C

DATA

LOGGING

D

FUNCTIONS

E

ANTI-

CYCLE

Description

1 User Code 13 Yes Yes Yes Yes
2 Date and Time 13 Yes Yes Yes Yes
3 Software Version 13 Yes No Yes Yes
4 Temperature Units 13 Yes Yes Yes Yes
1 Pool Setpoint 13 Yes Yes Yes Yes

2 PH Min Setpoint 13 No No Yes Yes
3 PH Max Setpoint 13 No No Yes Yes
4 PH Offset 13 No No Yes Yes
5 PH Differential 13 No No Yes Yes
6 Manual Reset High Limit 13 Yes Yes Yes Yes
7 PH Supply Hi Limit 13 No No Yes Yes

1 Hours Run PH 13 No No Yes Yes
2 Ignition Attempts 14 No No Yes Yes
3 Last 10 Lockouts 14 No No Yes Yes

1 Clear Error Log 14 No No Yes Yes
2 Service Delay 14 No No Yes Yes
3 Display Time 14 No No Yes Yes
4 Bypass Time 14 No No Yes Yes
5 Freeze Pump 14 No No Yes Yes
6 Freeze Burn 14 No No Yes Yes
7 Freeze Diff 14 No No Yes Yes
1 Anti Cycle Time 15 No Yes Yes Yes
2 Overide Diff 15 No Yes Yes Yes
3 Min On/Off Delay Stages 1, 3 15 Yes No Yes Yes
4 Next On Delay 15 Yes No Yes Yes

1 Cascade 15 No No Yes Yes

See

Page

User Access Installer Access

Display Modify Display Modify

F

MODES

CONTROL

G

CASCADE

H

CIRC.

PUMP

SERV.

NOTIFICATION

12

2 Modbus 15 No No Yes Yes
3 Modbus Time 15 No No Yes Yes

1 Boiler Address 15 No No Yes Yes
2 Max Cascade Setpoint 15 No No Yes Yes
3 Cascade Offset 15 No No Yes Yes
4 Cascade Diff 15 No No Yes Yes
1 PH Pump Delay 16 No No Yes Yes

2 PH Pump Off 16 No No Yes Yes
3 PH Pump Purge 16 No No Yes Yes
1 Service Interval Time 16 No No Yes Yes

2 Service Interval Run 16 No No Yes Yes

I

3 Service Operations 16 No No Yes Yes
4 Reset Service 16 No No Yes Yes
5 Accept PPlug 16 No No Yes Yes

Copper-fin II/IIE Pool Heater 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.

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

B: Temperature settings

B1: Pool Set point

The PH user set point sets the pool temperature set point.
This parameter can be changed by the user or the installer
by accessing parameter B1. The temperature range of this
parameter is 50°F (10°C) to 108°F (42°C). The default value is
80°F (27°C).

B3: PH Maximum set point

The PH maximum set point sets the maximum water temperature
set point that can be used for pool heater operation. The user
or installer will not be able to program the control with a higher
PH 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 108°F (42°C). The default value
is 108°F (42°C).

B4: PH Offset

The PH 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 2°F (1°C).

B5: PH Differential

The PH 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 4°F
(2°C).

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). The default value is 200°F (93°C).

B7: PH supply high limit

The SMART SYSTEM control also includes an integrated auto
reset high limit (ARHL) feature, based on the pool supply
temperature. The temperature range of this parameter is

101.3°F (38°C) to 110°F (43°C). The default value is 110°F
(43°C).

C: Data logging

C1: Hours running PH

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

B2: PH Minimum set point

The PH minimum set point sets the minimum water temperature
set point that can be used for pool heater operation. The user
or installer will not be able to program the control with a lower
PH 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 105°F (40°C). The default value
is 70°F (21°C).

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1 Service

Copper-fin II/IIE Pool Heater Service Manual

C2: Ignition attempts

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 C2.

C3: 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 C3.

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 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.

D5: Freeze protection pump on

In order to prevent the water in the heater from freezing, the
SMART SYSTEM control turns on the unit 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 starting
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).

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

A 3-way bypass valve is installed between the outlet and
the inlet of the heater. The SMART SYSTEM control is
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. When using the
factory installed bypass valve, no adjustment is required. The
range of this parameter is 0 to 255 seconds. The default value
is 20 seconds.

14

1 Service (continued)

Copper-fin II/IIE Pool Heater Service Manual

E: Anti-cycling

E1: Anti-cycle time

Once a PH demand has been satisfied, a set amount of time
must elapse before the control will respond to a new 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 E2. This parameter
can be changed by the installer by accessing parameter E1. The
time range for this parameter is 0 minutes to 40 minutes. The
default value is 1 minute.

E2: Anti-cycle override differential

The control will bypass the anti-cycling time if the inlet water
temperature drops too far. 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 E2. The
temperature range of this parameter is 0°F (0°C) to 54°F (30°C).
The default value is 10°F (5°C).

E3: Minimum on / off delay 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 E3. The
range of this parameter is 0 to 255 seconds. The default value is
60 seconds.

E4: 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 E4. The range of this parameter is
0 to 255 seconds. The default value is 60 seconds.

F: Control modes

F1: Cascade (active / inactive)

Pool 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 F1. The default value is Inactive.

F3: 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 F3. The range of this
parameter is 0 to 120 seconds. The default value is 10 seconds.

G: Cascade

G1: Boiler address

The heater designated as the Leader needs to be programmed
with address 0. All the Member heaters 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 G1. The default address
is 1.

G2: Max. outlet set point

When pool heaters are connected in a Cascade, this parameter
determines the set point used by the individual heaters. When a
heater is commanded to fire by the Leader heater, it will attempt
to achieve this temperature at its outlet. The Leader heater will
limit the modulation of the last heater to fire in order to hold
the temperature at the pool sensor to the user set point. If
any of the heater outlet temperatures reach the max. cascade
set point, the heater 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 heaters in a Cascade. This parameter
is adjustable by the installer by accessing parameter G2. 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).

G3: Cascade offset

This parameter determines how much the temperature
must go above set point before the lead heater will turn off.
This parameter can be adjusted by the installer by accessing
parameter G3. The temperature range for this parameter is 0°F
(0°C) - 54°F (30°C). The default value is 9.9°F (5°C).

F2: 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 F2
must be set to ACTIVE. The default value is Inactive.

G4: Cascade differential

This parameter determines how much the temperature must
go below the turn off temperature (Set point + Offset) before
the lead heater turns on. This parameter can be adjusted by the
installer by accessing parameter G4. The temperature range for
this parameter is 0°F (0°C) - 54°F (30°C). The default value is

19.8°F (11°C).

15

1 Service

Copper-fin II/IIE Pool Heater Service Manual

H: Circulation pumps

H1: PH pump delay

The system pump delay parameter sets the length of time the
unit pump (if connected) will run after a PH demand has
been satisfied. This parameter is adjustable by the installer by
accessing parameter H1. The time range for this parameter is 1
minute to 40 minutes. The default time is 30 seconds.

H2: PH pump off

The SMART SYSTEM control can force the unit pump to run
for a set period of time before firing the heater, if the pump had
been off for too long. To set the length of time the unit pump
must be off before this feature becomes active, the installer
must access parameter H2. The time range for this parameter
is 0 minutes to 240 minutes. The default value is 0 minutes
(disabled).

H3: PH pump purge

Once the time period defined by parameter H2 has elapsed,
the SMART SYSTEM control will turn the unit pump on at the
start of the next call for heat, then wait a period of time before
firing the heater. This delay time can be adjusted by the installer
by accessing parameter H3. The time range for this parameter
is 0 minutes to 240 minutes. The default value is 0 minutes
(disabled).

I4: 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 I4. Once accessed, press the
RESET key to reset the service notification counter.

I5: 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”. Locate the label attached to the front of the control
panel showing the personality ID number of that unit. Note
the number written on the label. Access parameter I5. That
number should appear after the word “Setting:” on the bottom
line. If this number matches the number on the label, press
“Enter”.

I: Service Notification

I1: Service interval time (months)

When the heater control determines that a scheduled service is
due based on days of installation, the heater display will alternate
the standard display text with the message SERVICE DUE every
5 seconds. This parameter is adjustable by the installer by
accessing parameter I1. The time range for this parameter is 0
months to 36 months. The default time is 12 months.

I2: Service runtime (hours)

When the heater control determines that a scheduled service
is due based on the hours of actual operation, the display will
alternate the standard display text with the message SERVICE
DUE every 5 seconds. This parameter is adjustable by the
installer by accessing parameter I2. The time range for this
parameter is 0 hours to 100,000 hours. The default time is
10,000 hours.

I3: Service operations

When the heater control determines that a scheduled service
is due based on the number of cycles, the display will alternate
the standard display text with the message SERVICE DUE every
5 seconds. This parameter is adjustable by the installer by
accessing parameter I3. The range for this parameter is 0 cycles
to 100,000 cycles. The default is 10,000 cycles.

16

Copper-fin II/IIE Pool Heater 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

17

2 Maintenance

Copper-fin II/IIE Pool Heater Service Manual

 WARNING

 WARNING

 WARNING

CAUTION

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.

Be sure to shut the pool heater OFF when backwashing the filter.

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

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.

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

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. 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.

18

Copper-fin II/IIE Pool Heater 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
heater 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.

19

2 Maintenance

Copper-fin II/IIE Pool Heater 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.

20

Copper-fin II/IIE Pool Heater 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 - 500,000 - 750,000 Btu/
hr Models

LESS AIR

On the 500,000 - 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

21

2 Maintenance

Copper-fin II/IIE Pool Heater 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 500,000 - 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 on
page 23.

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.

22

Copper-fin II/IIE Pool Heater 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

502 - 752 1.8'' w.c. 4.6’’ w.c.

992 - 2072 1.2'' w.c. 4.6’’ w.c.

23

Copper-fin II/IIE Pool Heater 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.

24

3 Troubleshooting

Copper-fin II/IIE Pool Heater 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. Check for 24 VAC

between S1 terminal 9 on the connection board and ground.

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

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

4. Make sure all external limit controls are installed and

operating.

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.

F2

3.15 AMPS

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 heater operation (Start-up Section in the Installation
and Operation Manual) after completing heater service.

25

Copper-fin II/IIE Pool Heater 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.

- Unit locked out on fault.

- Heater 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 25 of this manual.

• Review temperature setting.

• Review remote thermostat setting.

• Consult display for specific fault. Refer to fault
descriptions on pages 29 - 35 of this manual for
corrective actions.

• Check BMS parameter settings. Optional PC
software required.

26

Copper-fin II/IIE Pool Heater 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/Pool Return/Supply A

(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

S1b Outlet/Pool Supply B

(Wire Color - Bk and G)

27

Copper-fin II/IIE Pool Heater Service Manual

3 Troubleshooting

Table 3C Troubleshooting Chart - Noisy System

FAULT CAUSE CORRECTIVE ACTION

- Gas supply problem. • Refe r 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 21 and 22 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 20 and 21 in this manual for the burner

Noisy

Operation

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

No Pump

Operation

Relief Valve

Opening

- 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.

- Outlet water temperature in excess of 210°.

• Replace relay.

• Replace pump.

• Check fuse F5.

• Replace main control board.
Note: Make sure the heater 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.

• 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.

28

Copper-fin II/IIE Pool Heater Service Manual

3 Troubleshooting (continued)

Table 3D 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.

29

Copper-fin II/IIE Pool Heater Service Manual

3 Troubleshooting

Table 3D (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 19 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 20 and 21
of this manual for removal and cleaning procedures.
Replace if necessary.

• Refer to the Checking Manifold Gas Pressure and
Combustion Procedure on pages 21 and 22
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

30

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 Pool Heater Service Manual

3 Troubleshooting (continued)

Table 3D (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 19 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 21 and 22
of this manual for the proper settings.

• Inspect the burners. Reference pages 20 and 21
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 heater 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
heater flow.

• Check temperature setting of the main control
board.

• Check resistance of water sensors and compare to
Table 3B on page 27 of this manual. Replace
sensor if necessary.

• Replace outlet sensor.

31

Copper-fin II/IIE Pool Heater Service Manual

3 Troubleshooting

Table 3D (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.)

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

• 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 heater flow.

• Check temperature setting of the main control board.

• Check resistance of water sensors and compare to
the tables on page 27 of this manual. Replace the
sensor if necessary.

• Replace outlet sensor or high limit.

• Check the wiring between the low voltage connection
board and the 3-way valve.

Inlet Low

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

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

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.

• Verify that the control applies 24 VAC between the
“Close” terminal and the “COM” terminal on the 3-way
valve after the heater fires. If 24 VAC is present and
the valve does not move, replace the valve.

• 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 27 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 27 of this
manual.

• Replace the sensor if necessary.

32

Copper-fin II/IIE Pool Heater Service Manual

3 Troubleshooting (continued)

Table 3D (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.

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.)

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 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.

• 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.

Wrong ID Plug

Control module ID plug does not match
parameter L5.

• Verify that the number on the label on the control
panel matches the number in parameter I5. If not,
replace the control module.

• When replacing control modules, verify that the
number in parameter I5 matches the number on the
label on the control panel (reference page 16 of this
manual). If so, press the ENTER button on the SMART
SYSTEM display. If not, replace the control module.

33

Copper-fin II/IIE Pool Heater Service Manual

3 Troubleshooting

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

FAULT DESCRIPTION CORRECTIVE ACTION

• 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
filter system. Refer to the Water Connections
Section of the Installation and Operation Manual for the

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

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.)

Outlet water temperature has exceeded the
maximum outlet water temperature.

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
filter 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

Parameters Progr

(Will require a manual

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

SMART SYSTEM

to reset.)

display

External control is cycling too often.

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

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

• Replace the main control board.

• Check set point of the external control.

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

• Replace the control.

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

34

Copper-fin II/IIE Pool Heater Service Manual

3 Troubleshooting (continued)

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

FAULT DESCRIPTION CORRECTIVE ACTION

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

• 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 filter
system. Refer to the Water Connections Section of

Service Blk

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

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

Watch Dog Error

Write EEProm

Program EEProm

CRC Parameters

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

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.

• 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.

• 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.

No Error Stored

The main control board has detected an
internal fault.

• Press RESET.

• Cycle main power.

• Replace the main control board.

35

Revision Notes: Revision A (ECO #C11226) initial release.

Revision B (ECO C13449) reflects the addition of the backwash caution
on page 18.

Revision C (ECO C15759) reflects the update of high limit parameter
settings on page 13.

Revision D (CN 500000379) reflects the modification of text within the
Troubleshooting Section on page 30 and clarification of Combustion
information on pages 21 and 22.

CPX-SER Rev D / MM# 100160933 Rev D / DIR# 2000001949 Rev D

05/15