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.
2
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.
3
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
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 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
5
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
6
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)
7
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.
8
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: Standby
OUT: 123.8F(129)
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)
9
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)
10
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.
11
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
12
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
Menu
Sub
Item
A
GENERAL
B
SETTINGS
TEMPERATURE
C
DATA
LOGGING
D
FUNCTIONS
E
DHW SETTINGSOUTDOOR RESET
F
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
13
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
Menu
G
H
I
J
K
L
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
14
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