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.

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.

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

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

1 Service

Control inputs

POOL SUPPLY SENSOR

POOL SENSOR

CASCADE

Copper-fin II/IIE Pool Heater Service Manual

SENSOR CONNECTION

LOW

VOLTAGE

CONNECTION

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

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)

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.

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: 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)

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

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

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