Lochinvar PB1002 Service Manual

PBX-PFX-SER Rev F

Service Manual

Models: 502, 752, 1002,

1302, 1501, 1701, and 2001

Up To 5:1 Turndown

 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 Power-fin 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.

Service Manual

Contents

Contents ............................................................................................................... 2

Hazard definitions ................................................................................................ 2

Please read before proceeding ........................................................................... 3

What is in this manual? ....................................................................................... 4

1. . Service ............................................................................................................ 5

2. . Maintenance.................................................................................................... 22

3. . Troubleshooting .............................................................................................. 31

Troubleshooting Chart - No Display ................................................................ 32

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

Troubleshooting Chart - Noisy System ........................................................... 34

Troubleshooting Chart - Fault Messages ....................................................... 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.

Please read before proceeding

Service Manual

 WARNING

NOTICE

Installer – Read all instructions, including this manual and the Powerfin 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 Power-fin 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 Power-fin Installation and Operation Manual).

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

When servicing appliance –

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

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

Appliance operation –

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

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

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

Appliance water –

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

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

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

What is in this manual?

Service Manual

Service

The Power-fin display

• Display panel readout, buttons and their functions

Control module inputs

• Control module inputs and options

Control module outputs

• Control module outputs and options

General

• How the appliance operates

• How the control module operates

• Access modes -- user and installer

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

Control panel menu access

• Accessing programming mode and locating menus (See separate guides covering the PC and pocket 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.

Power-fin operation

• A: General

• B: Temperature Setting

• C: Data Logging

• D: Functions

• E: DHW Settings

• F: Outdoor Air Reset Curve

• G: Anti-cycling

• H: Control Modes

• I: Cascade

• J: Building Management System (BMS)

• K: Circulation Pumps

• L: Service Notification

Maintenance

• Service and maintenance schedules

• Address reported problems

• Inspect appliance area and appliance interior

• Clean condensate trap

• Check all piping for leaks

• Flue vent system and air piping

• Check water system

• Check expansion tank

• Check control settings

• Check igniter

• Check all appliance wiring

• Check flue gas passageways

• Flame inspection

• Inspect and clean burner

• General maintenance

• Checking manifold gas pressure

• Combustion analysis procedure

• Gas valve adjustment procedure

• 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

1 Service

The Power-fin display

Service Manual

1 Service

Control inputs

Service Manual

1 Service (continued)

Control outputs

Service Manual

1 Service

General Operation

Service Manual

How the appliance operates

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

How the control module operates

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

Sequence of operation

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

Access modes

User

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

Installer

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

Saving parameters

To save parameters and exit programming:

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

To keep parameter settings only for a current operating cycle:

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

To enter a parameter and continue programming:

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

1 Service (continued)

Sequence of operation

Table 1A_Sequence of Operation - Space Heating and DHW

OPERATION DISPLAY

Service Manual

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

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

3. • If the unit is equipped with a proof of closure valve, the proof of closure switch must be closed. The proof of closure valve is then energized. The gas pressure switch(es) (if equipped) must close.

• If the contact for the louvers is closed, the louver proving, blocked drain switch, and auto reset high limit (water heater only) inputs must close.

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

4. After the 10 second prepurge, the blower slows down and the hot surface igniter (HSI) is energized. The HSI is heated for at least 15 seconds.

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

HTR: Standby OUT: 123.8F(129)

HTR: PREPURGE OUT: 123.9F(129)

HTR: IGNITION OUT: 123.9F(129)

6. If the SMART SYSTEM control does not sense flame within 7 seconds of the opening of the gas valve, then it will lock out.

7. If the SMART SYSTEM control senses flame within 7 seconds, it will fire the burner to maintain the set point. On B9 and M9 models, the firing rate will modulate as required to hold the actual temperature at the set point. If the boiler lights due to a space heating call for heat, and the ramp delay function is active (default is disabled), the modulation will be held to a series of increasing limits after the burner has lit.

8. If the space heating call for heat is active, and the DHW thermostat closes, the control will turn on the DHW pump, wait 2 seconds, and then turn off the boiler pump. This will divert the hot water away from the heating zone(s) and send it to the DHW tank instead. The control will then modulate (B9 and M9 models only) to maintain the outlet temperature to the DHW boiler set point.

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

HTR: SH 20% RATE OUT: 124.8F(129)

HTR: DHW 85% RATE OUT: 177.8(180)

1 Service

Sequence of operation

Table 1A_(continued from previous page) Sequence of Operation - Space Heating and DHW

OPERATION DISPLAY

9. If the DHW thermostat remains on for more than 30 minutes, and the space heating call for heat is also on, then the control will turn on the boiler pump, turn off the DHW pump after 2 seconds, and resume firing based on the space heating set point. As long as both the space heating and DHW calls for heat remain active, the control will switch back and forth between the two modes until one of them is satisfied.

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

HTR: SH 41% RATE

OUT: 123.0F(129)

HTR: POSTPURGE

OUT: 127.4F(129)

Service Manual

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

12. System pump off.

HTR: Standby

OUT: 124.7F(129)

HTR: Standby

OUT: 122.9F(129)

1 Service (continued)

Display panel menu access

Table 1B_Use this procedure to access menus from the display panel

Service Manual

Note: Not all menu listings shown above are available on water heaters.

Service Manual

1 Service

Display panel parameter access

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

Cascade BMS

1 Service (continued)

Parameter table

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

Service Manual

MENU SUB ITEM DESCRIPTION

1 Heater Model 15 Yes No Yes No 2 User Code 15 Yes Yes Yes Yes 3 Date and Time 15 Yes Yes Yes Yes

GENERAL

SETTING

TEMPERATURE

DATA

LOGGING

4 Software Version 15 Yes No Yes No 5 Temperature Units 15 Yes Yes Yes Yes 6 Night Setback Temperature 15 Yes Yes Yes Yes

7 Night Setback Times 15 Yes Yes Yes Yes

1 SH Set Point User 15 Yes Yes Yes Yes 2 SH Minimum Set Point 15 No No Yes Yes 3 SH Maximum Set Point 15 No No Yes Yes 4 SH Offset 15 No No Yes Yes

5 SH Differential 15 No No Yes Yes

1 Hours Running SH 16 Yes No Yes No 2 Hours Running DHW 16 Yes No Yes No 3 Ignition Attempts 16 Yes No Yes No 4 Show Last 10 Errors 16 Yes No Yes No

SEE

PAGE

USER ACCESS INSTALLER ACCESS

DISPLAY MODIFY DISPLAY MODIFY

1 Service Mode Delay 16 No No Yes Yes 2 Reset Last 10 Errors 16 No No Yes Yes

FUNCTIONS

1 DHW Tank Set Point 16 Yes Yes Yes Yes

DHW

SETTINGS

OUTDOOR AIR RESET

2 DHW Boiler Set Point 16 Yes Yes Yes Yes 3 SH/DHW Switching Time 16 Yes Yes Yes Yes

1 Minimum Air Temperature 16 No No Yes Yes 2 Maximum Air Temperature 16 No No Yes Yes 3 Maximum SH Set Point 17 No No Yes Yes 4 Minimum SH Set Point 17 No No Yes Yes

5 Outdoor Air Shutdown 17 Yes Yes Yes Yes 6 7 Shift Reset Curve 17 No No Yes Yes 8 Boost Temperature 18 Yes Yes Yes Yes 9 Boost Time 18 Yes Yes Yes Yes

Outdoor Air Shutdown Differential

17 Yes Yes Yes Yes

Service Manual

1 Service

Parameter table (continued)

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

MENU SUB ITEM DESCRIPTION

1 Anti-cycling Time 18 No No Yes Yes

Inlet Temperature Differential for Ending Anti-Cycling

SH Controlling Sensor (Outlet/ System, Inlet)

ANTI-CYCLING

MODES

CONTROL

CASCADE

2 3 Ramp Delay On/Off 18 No No Yes Yes

4 Ramp Delay Settings (boiler only) 18 No No Yes Yes

1 2 Enable Input 19 No No Yes Yes 3 0-10V Building Management Input 19 No No Yes Yes

4 Cascade 19 No No Yes Yes

1 Boiler Cascade Address 19 No No Yes Yes 2 Max. Cascade Set Point 20 No No Yes Yes

3 Cascade Offset 20 No No Yes Yes 4 Cascade Off-On Differential 20 No No Yes Yes

1 BMS Type 20 No No Yes Yes 2 Voltage at Minimum 20 No No Yes Yes

SEE

PAGE

18 No No Yes Yes

19 No No Yes Yes

USER ACCESS INSTALLER ACCESS

DISPLAY MODIFY DISPLAY MODIFY

3 Voltage at Maximum 20 No No Yes Yes 4 Minimum Power 20 No No Yes Yes

SYSTEM (BMS)

BUILDING MANAGEMENT

PUMPS

5 Maximum Power 20 No No Yes Yes

6 Minimum Set Point 20 No No Yes Yes

7 Maximum Set Point 21 No No Yes Yes

8 Voltage at Start 21 No No Yes Yes

9 Voltage at Stop 21 No No Yes Yes

1 System Pump Delay 21 No No Yes Yes 2 SH Pump Delay 21 No No Yes Yes 3 DHW Pump Delay 21 No No Yes Yes

CIRCULATION

1 Service Notification in Months 21 No No Yes Yes 2 Service Notification Running Hours 21 No No Yes Yes

SERVICE

NOTIFICATION

3 Service Notification Boiler Cycles 21 No No Yes Yes 4 Reset Service Notification Counter 21 No No Yes Yes 5 Accept PPlug 21 No No Yes Yes

+ 30 hidden pages