Lochinvar SMART SYSTEM 402 - 2072, SMART SYSTEM 502 - 2072 User Manual

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

Copper-fin II/IIE

Boiler, Water Heater

and Pool Heater

Service Manual

Models: 402 - 2072

(Boiler & Water Heater)

Models: 502 - 2072

(Pool Heater)

 WARNING

Save this manual for future reference.

This manual must only be used by a qualified heating installer / service technician. Read all instructions, including this manual and the Installation and Operation Manual, before installing. Perform steps in the order given. Failure to comply could result in severe personal injury, death, or substantial property damage.

Contents

CONTENTS ........................................................................ 2

Hazard Definitions .............................................................. 2

PLEASE READ BEFORE PROCEEDING ........................ 3

Handling Ceramic Fiber Materials ...................................... 3

When servicing appliance ............................................. 3

Appliance operation ..................................................... 3

Appliance water ............................................................ 3

WHAT IS IN THIS MANUAL .............................................. 4

1. SERVICE

The Copper-fin Display ...................................................... 5

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

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

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

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

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

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

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

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

Hazard definitions

2. MAINTENANCE

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

3. TROUBLESHOOTING

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

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

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

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

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

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

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

The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product.

 DANGER

 WARNING

 CAUTION

CAUTION

NOTICE

DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

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

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

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

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

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

Please read before proceeding

 WARNING

NOTICE

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

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

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

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

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

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

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

When servicing appliance –

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

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

Appliance operation –

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

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

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

Appliance water –

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

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

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

Handling ceramic fiber materials

REMOVAL OF COMBUSTION CHAMBER LINING

 WARNING

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

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

Avoid breathing dust and contact with

skin and eyes.

• Use NIOSH certified dust respirator (N95).

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

Apply enough water to the combustion chamber lining to

 Remove the combustion chamber lining from the appliance

 Wash potentially contaminated clothes separately from

NIOSH stated First Aid.

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

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

protection.

prevent airborne dust.

and place it in a plastic bag for disposal.

other clothing. Rinse clothes washer thoroughly.

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

What is in this manual?

Service

The Copper-fin display

• Display panel readout, buttons and their functions

Control module inputs

• Control module inputs and options

Control module outputs

• Control module outputs and options

General

• How the appliance operates

• How the control module operates

• Access modes -- user and installer

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

Control panel menu access

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

Control panel parameter access

• Accessing and changing parameters from the display panel

Quick start information -- parameter table

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

Maintenance

• Service and maintenance schedules

• Address reported problems

• Inspect appliance area and appliance interior

• Check all piping for leaks

• Flue vent system and air piping

• Combustion air filter

• Check water system

• Check expansion tank

• Check relief valve

• Check igniter

• Check all appliance wiring

• Flame inspection

• Check flue gas passageways

• Inspect and clean burner

• Checking combustion air pressure

• Checking manifold gas pressure

• Cleaning heat exchanger

• Review with owner

Troubleshooting

• Troubleshooting table - No display

• Checking temperature sensors

• Troubleshooting table - Noisy system

• Troubleshooting table - Fault messages displayed on Operator Interface

Copper-fin operation

• A: General

• B: Temperature Settings

• C: Data Logging

• D: Functions

• E: DHW Settings

• F: Outdoor Air Reset

• G: Anti-cycling

• H: Control Modes

• I: Cascade

• J: Building Management System (BMS)

• K: Pumps

• L: Service Notification

1 Service

The Copper-fin display

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

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

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

• Press to turn heater off or back on

• Press to select a menu item

• Press after parameter programming to store parameter data

• Press to exit Service Mode

MENU/EXIT

DISPLAY SCREEN

ENTER/RESET

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

• Press to change displayed data values in Menu Mode

• Press to navigate through menu listing in Menu Mode

TXENSUOIVERPNWODPU

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

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

• Press and hold both to enter Service Mode

1 Service

Control inputs

OUTDOOR SENSOR (OPTIONAL)

SYSTEM SUPPLY/ ENABLE SENSOR (OPTIONAL)

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

SYSTEM PUMP SPEED (OPTIONAL)

CASCADE

DHW THERMOSTAT (OPTIONAL)

ROOM THERMOSTAT/ ZONE CONTROL (OPTIONAL)

SEQUENCER BUILDING MANAGEMENT S YSTEM (FIELD PROVIDED)

LOUVER PROVING SWITCH (FIELD PROVIDED)

TANK SENSOR (OPTIONAL)

MODBUS

INLET TEMPERATURE SENSOR

OUTLET TEMPERATURE/ LIMIT SENSOR

LOW WATER CUTOFF (OPTIONAL)

GAS PRESSURE SW ITCH (OPTIONAL)

MANUAL RESET HIGH LIMIT (OPTIONAL)

AIR PRESSURE SWITCH

FLOW SWITCH

DISPLAY PANEL

PC INTERFACE (OPTIONAL)

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

SENSOR CONNECTION BOARD (BOILER AND POOL HEATER ONLY)

SMART SYSTEM CONTROL BOARD

MODBUS

BOARD

(OPTIONAL)

LOW

VOLTAGE

CONNECTION

BOARD

1 Service (continued)

Control outputs

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

MODBUS

BOARD

(OPTIONAL)

SMART

SYSTEM

CONTROL

BOARD

LOW

VOLTAGE

CONNECTION

BOARD

MODBUS

0-10V

POWER

CASCADE

THREE WAY VALVE

(OPTIONAL ON BOILER)

(STD ON POOL HEATER)

LOUVER RELAY

BUILDING

MANAGEMENT

SYSTEM

RUN TIME CONTACTS

ALARM CONTACTS

ALARM

(OPTIONAL)

HEATER PUMP

(BOILER ONLY)

SYSTEM PUMP

RELAY

DHW PUMP RELAY

(BOILER)

DHW PUMP

(WATER HEATER)

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

HOT SURFACE

IGNITER

BLOWER

GAS VALVES

DISPLAY PANEL

PC INTERFACE

(OPTIONAL)

1 Service

General Operation

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

How the appliance operates

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

How the control module operates

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

Sequence of operation

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

Access modes

User

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

Installer

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

Saving parameters

To save parameters and exit programming:

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

To keep parameter settings only for a current operating cycle:

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

To enter a parameter and continue programming:

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

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

1 Service (continued)

Sequence of operation

Table 1A_Sequence of Operation - Space Heating and DHW

OPERATION DISPLAY

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

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

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

• The louver proving input must close.

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

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

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

HTR: Standby OUT: 123.8F(129)

HTR: PREPURGE OUT: 123.9F(129)

HTR: IGNITION OUT: 123.9F(129)

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

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

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

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

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

HTR: DHW STG 123 OUT: 177.8(180)

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

1 Service

Sequence of operation

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

OPERATION DISPLAY

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

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

HTR: RUN STG 12

OUT: 123.0F(129)

HTR: POSTPURGE

OUT: 127.4F(129)

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

12. System pump off.

HTR: Standby

OUT: 124.7F(129)

HTR: Standby

OUT: 122.9F(129)

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

1 Service (continued)

Display panel menu access

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

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

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

1 Service

Display panel parameter access

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

Cascade BMS

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

1 Service (continued)

Parameter table

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

Sub

Item

GENERAL

SETTINGS

TEMPERATURE

DATA

LOGGING

FUNCTIONS

DHW SETTINGSOUTDOOR RESET

Description

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

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

See

Page

User Access Installer Access

Display Modify Display Modify

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

1 Service

Parameter table (continued)

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

ANTI-CYCLING

MODES

CONTROL

CASCADEBMS

PUMPS

SERVICE

NOTIFICATION

Sub

Item

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

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

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

Description

See

Page

User Access Installer Access

Display Modify Display Modify

+ 30 hidden pages