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Lochinvar 402 - 2072 Patio Heater User Manual

1. 10 Copper fin 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 BUTTON OPERATION DISPLAY COMMENTS rears R O Heater turns off this ensures Q ENTER RES Press 1 time in normal operation 7 uninterrupted programming Enter Menu Code Digit shown underlined at left will NEN MENU EXIT Hold for 5 seconds display will change 0000 PE flash UP Press 9 times to change last digit Enter Menu Code Digit shown underlined at left will in readout to 9 0009 flash Press 2 times to move to the second Enter Menu Code Digit shown underlined at left will Previous did igit 0009 flash UP Press 3 times to change second digit Enter Menu Code Digit shown underlined at left will in readout to 3 0309 flash PREVIOUS Press 1 time to change to the first Enter Menu Code Digit shown underlined at left will digit 0309 flash gt Press 5 times to change first digit Enter Menu Code Digit shown underlined at left will A in readout to 5 5309 flash If you enter a digit incorrectly you can move to the digit by using the NEXT and PREVIOUS buttons as needed until the digit you want is flashing Then use UP and or DOWN buttons to change the value Enter Menu Code The words INSTALLER CODE ENTER RES Press to enter t
2. runs the system pump whenever there is a SH demand WWSD runs the system pump continuously except when the boiler is blocked due to outdoor shutdown To adjust the System Pump Mode access parameter K4 The default mode is CFH L Service Notification L1 Service calendar time months When the boiler control determines that a scheduled service is due based on days of installation the boiler display will alternate the standard boiler display text with the message SERVICE DUE every 5 seconds This parameter is adjustable by the installer by accessing parameter L1 The time range for this parameter is 0 months to 36 months The default time is 12 months L2 Service runtime hours When the boiler control determines that a scheduled service is due based on the hours of actual operation the boiler display will alternate the standard boiler display text with the message SERVICE DUE every 5 seconds This parameter is adjustable by the installer by accessing parameter L2 The time range for this parameter is 0 hours to 100 000 hours The default time is 10 000 hours L3 Service cycles When the boiler control determines that a scheduled service is due based on the number of boiler cycles the boiler display will alternate the standard boiler display text with the message SERVICE DUE every 5 seconds This parameter is adjustable by the installer by accessing parameter L3 The range for this parameter is 0 cycles to 100 000 cycl
3. Cycle main power Replace the main control board 42 Lochinvar V High Efficiency Water Heaters Boilers and Pool Heaters 300 Maddox Simpson Parkway Lebanon TN 37090 615 889 8900 Fax 615 547 1000 www Lochinvar com Revision Notes Revision A ECO C08226 initial release Revision B ECO C08896 reflects the update of Parameter Table 1 D on pages 13 14 and Parameter information on pages 17 and 19 Table 3B on page 33 for sensor information was also updated C F H P X SER Rev B 9 11
4. OPTIONAL ON BOILER LOW BOILER AND STD ON POOL HEATER BERNER POOL HEATER ONLY SYSTEM PUMP SPEED BOARD OPTIONAL CASCADE DHW THERMOSTAT OPTIONAL ROOM THERMOSTAT ZONE CONTROL OPTIONAL SEQUENCER BUILDING MANAGEMENT SYSTEM FIELD PROVIDED LOUVER PROVING SWITCH FIELD PROVIDED TANK SENSOR OPTIONAL MODBUS MODBUS BOARD OPTIONAL INLET TEMPERATURE SENSOR OUTLET TEMPERATURE LIMIT SENSOR LOW WATER CUTOFF OPTIONAL GAS PRESSURE SWITCH OPTIONAL MANUAL RESET HIGH LIMIT OPTIONAL AIR PRESSURE SWITCH FLOW SWITCH DISPLAY PANEL PC INTERFACE OPTIONAL EE A ASAN Copper fin Boiler Water Heater and Pool Service Manual 1 Service continued Control outputs LOW MODBUS VOLTAGE BOARD CONNECTION OPTIONAL BOARD SMART SYSTEM CONTROL BOARD HE amp 06904 6 6 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 HOT SURFACE IGNITER BLOWER GAS VALVES DISPLAY PANEL PC INTERFACE OPTIONAL e INDICATES CONNECTIONS MADE TO THE LINE VOLTAGE TERMINAL STRIP LOCATED IN THE CONTROL PANEL AREA Copper fin Boiler Water Heater an
5. 99 C for boilers and water heaters or 200 F 93 for pool heaters B7 Auto reset high limit The SMART SYSTEM control also includes an integrated auto reset high limit ARHL feature based on outlet temperature The ARHL set point is fixed at 205 F 96 C for water heaters and 185 F 85 C for pool heaters For boilers the temperature range of this parameter is 32 F 0 C to 235 F 113 C The default value is 200 F 93 C Data logging C1 Hours running SH The hours running SH parameter shows the total number of hours the unit has been in the SH firing mode This parameter can be viewed by the user and the installer by accessing parameter C2 Hours running DHW The hours running DHW parameter shows the total number of hours the unit has been in the DHW firing mode This parameter can be viewed by the user and the installer by accessing parameter C2 16 C3 Burner cycles 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 C3 C4 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 C4 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
6. accessing parameter F3 The temperature range of this parameter is 32 F 0 C to 248 F 120 C The default value is 180 F 82 C F4 Minimum SH set point When the outdoor temperature rises to or above its maximum setting F2 the water temperature will be at this value FIG 1 1 This parameter can be changed by the installer by accessing parameter F4 The temperature range of this parameter is 32 F 0 C to 248 F 120 C The default value is 70 F 21 C F5 Outdoor air shutdown When the outdoor temperature rises above this point the control will block all SH demands DHW demands will still be active This parameter can be changed by the user or the installer by accessing parameter F5 The temperature range of this parameter is 32 F 0 C to 122 F 50 C The default value is 80 F 27 C Copper fin Boiler Water Heater and Pool Service Manual 1 Service continued F6 Outdoor air shutdown differential The outdoor air shutdown differential parameter is the number of degrees below parameter F5 the outdoor air temperature must go before the unit will respond to a SH demand This parameter can be changed by the user or the installer by accessing parameter F6 The temperature range of this parameter is 0 F 0 C to 90 F 50 The default value is 10 F 5 C F7 Shift reset curve The shift reset curve parameter shifts the actual set point above or below the calculated set point the number of d
7. at Minimum 2 Ne Ne ves Yes ESL stis ne ve Yes 4 PoweratLowVotage Ne Ne ves Yes e Setpoint at Low votags No No ve ve s votageto Stat OFH Nw Ne ve ve e votage Diferental GFH 2 no No ve ve 4 system Pump ods Ne ve ve L1 sets ieu tme mome me ves ve serie Tine 3 noo ve Yes 5 ow ow vs 5 4 Reset Sorice Reminder Ne Ne ve ve CONTROL SERVICE NOTIFICATION 14 Copper fin Boiler Water Heater and Pool Service Manual 1 Service continued Viewable and changeable control parameters Before changin arameters note the CAUTION amg par 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 be
8. b 6 T 8 The manual reset high limit optional must be closed before any action will take place 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 The gas pressure switch es if equipped must close The louver proving input must close f the air pressure switch is open the prepurge cycle then begins by starting the combustion blower Once started the air pressure switch must close 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 Once the HSI is hot the trial for ignition begins with the opening of the gas valve If the SMART SYSTEM control does not sense flame then it will lock out 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 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 heatin
9. fin Boiler Water Heater and Pool Service Manual 3 Troubleshooting Table 3E continued from previous page Troubleshooting Chart Fault Messages Displayed on Operator Interface FAULT DESCRIPTION CORRECTIVE ACTION The temperature rise across the heat Verify that the system is full of water and that all air exchanger has exceeded the set parameters has been properly purged from the system for the appliance 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 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 Temp O Shoot Lockout will reset If 120 VAC is present on a call for heat and the automatically after 5 pump is not operating replace the pump 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 Verify that the system is full of water and that all air maximum outlet water temperature 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 the proper piping methods Check 120 VAC to the pu
10. has been corrected Press the RESET button on the SMART SYSTEM display to reset 38 CORRECTIVE ACTION 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 boiler flow Check temperature setting of the main control board Check resistance of water sensors and compare to the tables on page 33 of this manual Replace the sensor if necessary Replace outlet sensor or high limit Raise temperature set point above 130 Install a 3 way valve or LTV valve per the piping diagram in the Water Connections Section of the Installation and Operation Manual 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
11. in this manual and component literature could result in severe personal injury death or substantial property damage A WARNING 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 A WARNING uM noted otherwise in this instruction manual Failure to turn off electrical power could result in electrical shock causing severe personal injury or death 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 2 Vacuum any sediment from inside the appliance and components Remove any obstructions Check all piping for leaks Eliminate all system or appliance leaks Continual fresh makeup water will reduce appliance life Minerals can build up in sections reducing heat transfer overheating heat exchanger and
12. 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 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 28 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 i A WARNING 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 If you must adjust the gas valve regulator pressure follow the steps below 1 Remove the cap covering the manif
13. 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 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 eI Cascade J Building Management System BMS Pumps L Service Notification 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 tabl
14. resistance to the tables on page 33 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 33 of this manual Replace the sensor if necessary Copper fin Boiler Water Heater and Pool Service Manual 3 Troubleshooting continued Table 3E continued from previous page Troubleshooting Chart Fault Messages Displayed on Operator Interface DESCRIPTION FAULT 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 Tank Open 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 Wrong ID Plug An optional remote proving switch is not making Sensors equipped with an internal limit such as the Lochinvar Squire Indirect Tank the limit has opened due to temperature 195 F or the sensor has become disconnected The air pressure switch did not make within
15. 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 boiler flow Check temperature setting of the main control board Check resistance of water sensors and compare to Table 3B on page 33 of this manual Replace sensor if necessary Replace outlet sensor Copper fin Boiler Water Heater and Pool Service Manual 3 Troubleshooting Table 3E continued from previous page Troubleshooting Chart Fault Messages Displayed on Operator Interface The outlet water temperature has exceeded the setting of the adjustable high limit 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 inlet water temperature did not exceed 130 within 15 minutes of ignition Inlet Low Sensor Open Will require a manual reset once the condition has been corrected Press the RESET button on the Either the inlet water outlet water system supply system return or outdoor temperature sensor has been disconnected SMART SYSTEM display to reset Either the inlet water outlet water system supply system return or outdoor temperature sensor has been shorted Sensor Shorted Will require a manual reset once the condition
16. then return to the SH demand if active The default value of this parameter is 30 minutes E4 DHW SH switching time boiler only The time that the SMART SYSTEM control services a DHW demand before returning to the SH demand is set by parameter E4 The range of this parameter is 0 to 240 minutes Setting this parameter to 0 disables the switching function The default value of this parameter is 30 minutes E5 Tank offset water heater only The tank offset is the number of degrees the DHW tank temperature must go above the tank set point before the water heater will turn off To adjust this value access parameter E5 The temperature range of this parameter is 0 to 10 F 5 C The default value is 4 F 2 C E6 Tank differential The tank differential is the number of degrees the DHW tank temperature must go below the tank set point before the heater or boiler will start to heat the DHW tank To adjust this value access parameter E6 The temperature range of this parameter is 0 to 40 F 22 C The default value is 6 F 3 C 17 Copper fin Boiler Water Heater and Pool Service Manual 1 Service Figure 1 1 Outdoor Air Reset Curve WATER TEMPERATURE SET POINT MAXIMUM RESET Default 180 F USER SET POINT Default 120 F MINIMUM RESET Default 70 F Default 25 F OUTDOOR AIR AT MAXIMUM RESET F Outdoor air reset boiler only Outdoor air reset operation When the outdoor ai
17. 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 Control module ID plug does not match parameter L5 CORRECTIVE ACTION Check function of remote devices Check for loose or misplaced proving switch is not installed jumper if Check the tank temperature Repair or replace the sensor wiring if damaged Replace the sensor if necessary 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 Verify that the number on the ID plug matches the number in parameter L5 If not replace the control module When replacing control modules verify that the number in parameter L5 matches the number on the ID plug reference page 22 of this manual f so press the ENTER button on the SMART SYSTEM display If not replace the control module 39 Copper
18. 6 The temperature range for this parameter is 32 F 0 C 230 F 110 C boilers 32 F 0 C to 190 F 87 C water heaters or 32 F 0 C to 105 F 40 C pool heaters The default value is 70 F 21 C 21 Copper fin Boiler Water Heater and Pool Service Manual 1 Service J7 Set point at high voltage This setting determines the set point used by the unit or cascade when the BMS voltage is at or above the Voltage at Maximum setting This parameter is only active when the BMS type is set to Set Point This parameter can be adjusted by the installer by accessing parameter J7 The temperature range for this parameter is 32 F 0 230 F 110 C boilers 32 F 0 C to 190 F 87 C water heaters or 32 F 0 C to 105 F 40 C pool heaters The default value is 190 F 88 C for water heaters 220 F 104 C for boilers and 105 F 40 C pool heaters J8 Voltage to start CFH When the Enable input is set to Inactive this parameter determines the BMS input voltage at which the unit or cascade is enabled When the unit is disabled the unit will become enabled when the BMS input voltage rises up to or above this value This parameter may be adjusted by the installer by accessing parameter J8 The range for this parameter is J9 0 1V 10V The default value is 2V J9 Voltage differential CFH When the Enable input is set to Inactive this parameter determines the BMS input voltage at whi
19. C F H P X SER Rev B Copper fin II IIE Boiler Water Heater and Pool Heater Service Manual Models 402 2072 Boiler amp Water Heater Models 502 2072 Pool Heater 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 8 Y injury death or substantial High Efficiency Water Heaters Boilers and Pool Heaters property damage Save this manual for future reference CONTENTS ED ES 2 2 MAINTENANCE Hazard Definitions 2 Maintenance and Annual 23 30 PLEASE READ BEFORE PROCEEDING 3 3 TROUBLESHOOTING Handling Ceramic Fiber 3 Before Troubleshooting sessssssssss 31 When servicing 3 Check Control Module Fuses 31 Appliance operation 3 Table Troubleshooting Chart No Display 32 Appliance water eeeeennnnee 3 Checking Temperature Sensors 33 WHAT IS IN THIS MANUAL ccsesceseseeeeeeeseeeeteeeeeees 4 Table 3D Troubleshooting Chart Noisy Syst
20. E Do not wet the refractory located on the inside of the combustion chamber 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 Make sure the frame runners seal securely where they contact the front and rear compartment refractory 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 EH 5 Em HEAT EXCHANGER Figure 2 5 Location of the Heat Exchanger Inside Jacket Review with owner 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 Remindthe 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 Copper fin Boiler Water Heater and Pool Se
21. ENTER REs CSS time to save K2 SH Pump Dely K2 will flash or press MENU EXIT to continue Press 1 time to return to the main gt General B EE menu B Temp Settings MENU EXIT Press 1 time to return to normal HTR Pre Purge This display example assumes operation 00 123 7 a call for space heating is present 12 Copper fin 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 Descri tion See UserAccess Installer Access ipti Page Display Modify Display Modify 1 UserCode 15 Yes Yes Yes Yes Time and Date Ls ves o Ye Ye we oftware Version Temperature Units SH Night Setback Offset SH Night Setback Times HW Night Setback Offset HW Night Setback Times SH User Setpoint Minimum SH User Setpoint aximum SH User Setpoint SH Offset SH Differential anual Reset High Limit uto Reset High Limit ours Running SH ours Running DHW urner Cycles Last 10 Lockouts Reset Last 10 Lockouts ervice Mode Delay Display Timeout Bypass Valve Time reeze Protection Pump On reeze Protection Burner On reeze Protection Differential Tank Setpoint HW Boiler Setpoint H DHW Switching Time DHW SH Switching Time Tank Offset Tank Differential ie a 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2a 2 Al X o o
22. ERATION DISPLAY COMMENTS This example shows how to access parameter K2 SH pump delay The first display shown is at the beginning of the menu listings after entering the installer access code Beginning of menu listings PA General The caret symbol highlights Temp Settings the selectable line n The caret symbol gt highlights v DOWN Press 1 time to highlight second listing ih safactable lina v DOWN Press 1 time to toggle menu listing Tue mee menu options The menu toggles to the next two v DOWN Press 2 times to toggle menu listing menu options The menu toggles to the next two v DOWN Press 2 times to toggle menu listing 3 x menu options v DOWN Press 2 times to toggle menu listing Emito t TPE MENU Togdies du Ne B menu options p 21 Pump The menu toggles to the next two v DOWN ress 2 times to toggle menu listing KORG menu options Q ENTER RES Press 1 time to list parameters Pump De K1 will flash UP Press 1 time to change parameter K2 SH Pump Dely K2 will flash 5 o ENTER RES Press 1 time to select parameter K2 SH Pump Dely K2 will Stop flashing parameter 30 Seconds value will appear oe Mx UP Press to increase or decrease value K2 SH Pump Dely Parameter will increase or decrease or DOWN 40 Seconds depending on button pressed
23. Operation Manual Copper fin Boiler Water Heater and Pool Service Manual 3 Troubleshooting continued Table Troubleshooting Chart Fault Messages Displayed on Operator Interface FAULT DESCRIPTION CORRECTIVE ACTION Either the optional manual reset low gas Reset the pressure switches pressure switch or the optional manual reset high gas pressure switch tripped Measure the supply gas pressure to determine Gas Pressure SW cause of failure Refer to the Gas Connections Models 992 2072 natural gas Automatic Section of the Installation and Operation Manual for Will require a manual dedil Reset Low Gas is open detailed information concerning the gas supply reset once the condition has been corrected Correct the supply gas pressure if necessary Either the flow switch or the optional low Check pump operation on a call for heat water cutoff is not making LWCO e Check for closed valves or obstructions in the Lockout will reset water piping automatically after 5 minutes or may be e Verify system is full of water and all air has been reset immediately once purged from the system condition has been corrected Press the RESET button on the SMART SYSTEM display to reset The flame detector circuit is seeing a flame Check supply voltage for proper polarity signal while the gas valve is de energized Will require a manual Check that the gas valve is
24. T button on the SMART SYSTEM display to reset The outlet water temperature has exceeded the setting of the automatic reset high limit Auto Reset High Limit CORRECTIVE ACTION Inspect igniter and associated wiring for damage and connection Reference page 25 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 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 Refer to the Checking Manifold Gas Pressure and Combustion Analysis Procedure on pages 27 and 28 of this manual for the proper settings Inspect the burners Reference pages 26 and 27 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 ofthe Installation and Operation Manual for the proper piping methods for the Copper fin Check 120 VAC to boiler pump motor on a call for heat If voltage is not present check wiring back to
25. arameter along with the previous parameter determines how much the modulation or set point changes as the BMS input voltage changes The modulation or set point will change in proportion to the change in voltage between the minimum and maximum voltage settings This parameter may be adjusted by the installer by accessing parameter J3 The range for this parameter is J2 0 1V 10V The default setting is 10V J4 Power at low voltage This setting determines the modulation of the unit or cascade when the BMS input voltage is at or below the Voltage at Minimum setting This parameter is active only when the BMS type is set to Power This parameter may be adjusted by the installer by accessing parameter J4 The range for this parameter is 0 J5 The default value is 20 J5 Power at high voltage This setting determines the modulation of the unit or cascade when the BMS input voltage is at or above the Voltage at Maximum setting This parameter is only active when the BMS type is set to Power This parameter can be adjusted by the installer by accessing parameter J5 The range for this parameter is J4 100 The default value is 100 J6 Set point at low voltage This setting determines the set point used by the unit or cascade when the BMS voltage is at or below the Voltage at Minimum setting This parameter is only active when the BMS type is set to Set Point This parameter can be adjusted by the installer by accessing parameter J
26. causing heat exchanger failure Leaking water may also cause severe property damage 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 24 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 1 Verify all system components are correctly installed and operational 2 Check the cold fill pressure for the system Verify it is correct must be a minimum of 12 PSI 3 Watch the system pressure as the boiler heats up during testing to ensure pressure does no
27. ch the unit or cascade is disabled When the unit is enabled the unit will become disabled when the BMS input voltage drops down to or below the enable voltage minus this value This parameter may be adjusted by the installer by accessing parameter J9 The range for this parameter is J8 0 1V The default value is 1V K Circulation pumps K1 System pump delay The system pump delay parameter sets the length of time the system pump if connected will run after a SH demand has been satisfied or outdoor air shutdown begins This parameter is adjustable by the installer by accessing parameter K1 The time range for this parameter is 1 minute to 40 minutes The default time is 30 seconds K2 SH pump delay The SH pump delay parameter sets the length of time the boiler pump will run after a SH demand has been satisfied This parameter is adjustable by the installer by accessing parameter K2 The time range for this parameter is 1 minute to 40 minutes The default time is 30 seconds K3 DHW pump delay The DHW pump delay parameter sets the length of time the DHW pump boiler or unit pump water heater will run after a DHW demand has been satisfied This parameter is adjustable by the installer by accessing parameter K3 The time range for this parameter is 1 minute to 40 minutes The default time is 30 seconds 22 K4 System pump mode boiler only The system pump can be configured to operate in one of two modes
28. 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 either maximum firing rate or minimum 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 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 In low temperature systems a 3 way bypass valve can be installed between the outlet and the inlet of the heater see Installation and Operation Manual The SMART SYSTEM control can be set to automatically control this valve to maintain the inlet temp
29. closed reset once the condition has been corrected Press Check external wiring for voltage feedback the RESET button on the SMART SYSTEM display Check the internal wiring for bad connections to reset Replace main control board The main control board has received a call The control board will release the call for heat after for heat too quickly after the previous call for a set time period heat has ended Anti cycling The control board will release the call for heat if the outlet temperature drops too quickly 35 E Copper fin Boiler Water Heater and Pool Service Manual 3 Troubleshooting Table 3E continued from previous page Troubleshooting Chart Fault Messages Displayed on Operator Interface FAULT DESCRIPTION CORRECTIVE ACTION The unit has failed to prove burner flame Inspect igniter and associated wiring for damage and upon ignition connection Reference page 25 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 thatthe tube from the gas valve to the combustion air chamber is connected and is not damaged No Flame Ign Verify that the vent air intake pipes are correctly Will require a manual installed and that there are no ob
30. 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 HM Avoid breathing dust and contact with skin and eyes Use NIOSH certified dust respirator N95 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 Wear long sleeved loose fitting clothing gloves and eye protection Bl Apply enough water to the combustion chamber lining to prevent airborne dust Bl Remove the combustion chamber lining from the appliance and place it in a plastic bag for disposal Bl Wash potentially contaminated clothes separately from other clothing Rinse clothes washer thoroughly NIOSH stated First Aid Eye Irrigate immediately E Breathing Fresh air 3 Copper fin 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
31. d Pool Service Manual 1 Service General Operation 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
32. ddresses 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 I1 The outdoor air if used system supply sensor and system return sensor must be connected to the Leader boiler The default address is 1 I2 Max outlet set point When the system supply sensor is connected or the system supply temperature is provided through ModBus this parameter determines the set point used by the individual boilers in a Cascade When a boiler is commanded to fire by the Leader boiler it will attempt to achieve this temperature at its outlet The Leader boiler will limit the modulation of the last boiler to fire in order to hold the temperature at the system supply sensor to the user set point If any of the boiler outlet temperatures reach the max cascade set point the boiler 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 boilers in a Cascade Note that this parameter does not apply when the boiler is heating an indirect DHW tank This parameter is adjustable by the installer by accessing parameter 12 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 I3 Cascade offset boilers only This parameter determines how much the temperatu
33. de 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 boiler 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 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 Inspect replace hot s
34. e No display Checking temperature sensors Troubleshooting table Noisy system Troubleshooting table Fault messages displayed on Operator Interface Copper fin II IIE Boiler Water Heater and Pool Service Manual 1 Service The Copper fin display Hold 5 seconds to enter code Input Mode Menu Mode Press to turn heater off or back on Press to move up one level Press to select a menu item in Menu Mode or to exit Press after parameter programming Menu Mode to store parameter data Press to exit Service Mode MENU EXIT DISPLAY SCREEN ENTER RESET MEMU EXIT ENTER RESET D SYSTEM WP uP DOWN PREVIOUS PREVIOUS NEXT 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 UP DOWN 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 um Copper fin Boiler Water Heater and Pool Service Manual 1 Service Control inputs OUTDOOR SENSOR OPTIONAL SYSTEM SUPPLY ENABLE SENSOR OPTIONAL SENSOR SYSTEM RETURN CONNECTION POOL SENSOR BOARD
35. ect and clean the burners Check manifold gas pressures e Perform start up checkout performance verification per the Startup Section in the Installation and Operation Manual If combustion indicate need performance Clean heat exchanger with a stiff bristle brush Remove and clean burners water Dry before re assembling using Clean the blower wheel with a brush and vacuum Do not let dirt from cleaning get pulled into the blower Owner maintenance see the User s Information Manual for instructions Check appliance area Check pressure temperature gauge eck vent piping Check air piping Check relief valve Monthly Replace combustion air filter Note More frequent replacement may be necessary in dirty environments Do not use pleated filters Periodically Test low water cutoff if used Reset button low water cutoff Check appliance piping gas and Every water for leaks 6 months Operate relief valve Shut appliance down unless End boiler used for domestic hot of season water months 23 Copper fin Boiler Water Heater and Pool Service Manual 2 Maintenance Follow the service and maintenance procedures given throughout this manual and in component literature A WARNING 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
36. egrees in this parameter This parameter can be changed by the installer by accessing parameter F7 The temperature range of this parameter is 27 F 15 C to 27 F 15 The default value is O F 0 C This feature will be active if this parameter is set to anything other than 0 F 0 C F8 Boost temperature If a SH demand lasts longer than the programmed time delay setting F9 and there have been no DHW demands the control will increase the SH set point by the amount in this parameter If the SH demand continues through another time period the set point will be increased again This will continue until either the SH demand ends a maximum of 20 increases has occurred or the SH user set point has been reached Once the SH demand has been satisfied the set point will revert back to its calculated setting The boost temperature can be changed by the installer by accessing parameter F8 The temperature range of this parameter is 0 F 0 C to 45 F 25 C The default value is O F 0 C This feature will be active if this parameter is set to anything other than 0 F 0 C F9 Boost time The boost time parameter sets the amount of time that must elapse with a SH demand before the water temperature set point will be increased This parameter can be changed by the installer by accessing parameter F9 The time range for this parameter is 1 minute to 250 minutes The default value is 20 minutes G Anti cycling G1 Anti cycle dela
37. em 34 1 SERVICE Table Troubleshooting Chart Fault Messages 35 42 The Copper fin Display sess 5 Revision Notes cceseccesseceeseeeeesereeeeeeees Back Cover Control Irp ts 5 te ier rte t prts 6 Control OUPUTS aiani 7 General Operation iiti ninan 8 Sequence of Operation 9 10 Display Panel Menu Access 11 Display Panel Parameter 12 Parameter 13 14 Viewable and Changeable Control Parameters 15 22 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 A DANGER ae indicates an imminently hazardous situation which if not avoided will result in death or serious A WARNING WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury A CAUTION 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 CAUTION avoided may result in property damage NOTICE indicates special instructions on installation operation or maintenance
38. en 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 The internal clock does not adjust for NOTICE Daylight Savings Time and therefore will require a manual adjustment 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 A5 SH Night setback offset Once the internal clock has been set correctly the SH night setback feature can be used to program a lower set point The value of this parameter will be subtracted from the normal set point to determine the set point used during night setback This parameter can be changed by the user or the installer by accessing parameter A5 The temperature range for this parameter is 0 F to 90 F 50 C The feature is turned off with a setting of O F The default value is 0 F A6 SH Night setback times If parameter 5 is set to anything other
39. erature 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 The range of this parameter is 0 to 255 seconds The default value is 20 seconds Copper fin Boiler Water Heater and Pool Service Manual 1 Service continued D5 Freeze protection pump on In order to prevent the water in the heater from freezing the SMART SYSTEM control turns on the boiler 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 strating 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 m
40. es The default is 10 000 cycles L4 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 L4 Once accessed press the RESET key to reset the service notification counter L5 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 Look behind the control panel at the connector plugged into X5 on the control board Note the number written on the connector Access parameter L5 That number should appear after the word Setting on the bottom line If this number matches the number on the connector press Enter Copper fin Boiler Water Heater and Pool 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 condensate water gas flue Examine venting system Check system water pressure system piping expansion tank Check control settings Check igniters Check wiring and connections Check flue gas passageways lt lt 2 Flame inspection stable uniform Insp
41. eter A8 Each day of the week Monday through Sunday will have an on and off time If you wish to skip a day set the on and off times to the same time and prior to 12 00 p m To keep night setback active through the entire day set the on and off times to the same time and after 12 00 p m B Temperature settings boiler only B1 SH Set point user The SH set point user sets the water temperature or pool temperature set point for fixed operation or the maximum temperature set point when the outdoor air sensor is used This parameter can be changed by the user or the installer by accessing parameter Bl The temperature range of this parameter is 60 F 15 C to 230 F 110 C The default value is 80 F 27 B2 SH Minimum set point The SH minimum set point sets the minimum water temperature set point that can be used for space heating and pool heater operation The user or installer will not be able to program the control with a lower SH 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 230 F 110 C space heating or 32 F 0 C to 105 F 40 C pool heater The default value is 70 F 21 C 15 Copper fin Boiler Water Heater and Pool Service Manual 1 Service B3 SH Maximum set point The SH maximum set point sets the maximum water temperature set point that can be used for space heating The user or installer w
42. f 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 1l 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 NOTIC
43. g the unit 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 NOTICE 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 On the 399 999 750 000 Btu hr models NOTICE gt nonce 5 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 Check for proper installation and draft in the venting system prior to any adjustments Correct as needed Figure 2 2 Adjusting air shutter 399 999 750 000 Btu hr Models LESSAIR MORE AIR deem AIR SHUTTER Figure 2 3 Adjusting air shutter 990 000 2 070 000 Btu hr Models MORE AIR 7 R AIR SHUTTER ADJUSTING BRACKET 27 Copper fin Boiler Water Heater and Pool Service Manual 2 Maintenance 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 factor
44. g 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 Standby 123 8F 129 Standby 123 8F 129 Standby 123 8F 129 PREPURGE 123 9F 129 IGNITION 123 9F 129 POSTPURGE PREPURGE 123 9F 129 RUN STG 1 124 8F 129 DHW STG 123 177 8 180 Copper fin 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 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 RUN STG 12 space heating set point As long as both the space heating 123 0 129 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 POSTPURGE 30 second postpurge cycle Any pumps that are running 127 4F 129 will continue to run for their respective pump delay times 4F then turn off Boiler pump off system pump continues its delay if Standby longer 124 7F 129 Standby 12 Syst ff ystem pump o 122 9 129
45. he code will flash while displayed 2 After 2 seconds display shows menus gt A General The caret symbol gt highlights press ENTER RESET to select a menu B Temp Settings the selectable line If the code is entered incorrectly the display will return to its previous mode You will have to start over at step 1 to enter the code v DOWN Press 1 time to highlight second listing win ut E THe carer Sy iP Ol gt B Temp Settings the selectable line v DOWN Press 1 time to toggle menu listing gt C Data Logging The menu toggles to the next two D Functions menu options v DOWN Press 2 times to toggle menu listing gt E Settings The menu toggles to the next two F Outdoor Reset menu options v DOWN Press 2 times to toggle menu listing gt G Anti cycling The menu toggles to the next two H Control Modes menu options v DOWN Press 2 times to toggle menu listing zI cascade TREMANI sq eR NM J BMS menu options To select a highlighted menu press the ENTER RESET button one time The display will change to the first parameter under that menu with the first characters flashing Note Not all menu listings shown above are available on water heaters 11 Copper fin 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 BUTTON OP
46. ill not be able to program the control with a higher SH 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 230 F 110 C space heating or 32 F 0 C to 105 F 40 pool heater The default value is 220 F 104 C space heating or 105 F 55 C pool heater B4 SH Offset The SH 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 to 54 F 30 The default value is 10 F 5 C boiler or 2 F 1 C pool heater B5 SH Differential The SH 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 20 F 11 C boiler or 4 F 2 C pool heater B6 Manual reset high limit The SMART SYSTEM control includes an integrated manual reset high limit MRHL feature based on theoutlet temperature The set point for the MRHL is adjusted using parameter B6 The temperature range of this parameter is 32 F 0 to 210 F 99 for water heaters and pool heaters or 240 F 115 C for boilers The default value is 210 F
47. in another heater in a Cascade To adjust this time delay access parameter G4 The range of this parameter is 0 to 255 seconds The default value is 60 seconds 19 Copper fin Boiler Water Heater and Pool Service Manual 1 Service Figure 1 2 Ramp Delay Interval RATE RAMP 6 RAMP 5 RAMP 4 RAMP 3 RAMP 2 RAMP 1 TIME TIME 3 2 lt TIME FOR 1 HEAT H Control modes H1 SH controlling sensor boiler only The SH controlling sensor parameter selects the sensor the control will use to regulate the boiler firing rate This parameter is adjustable by the installer by accessing parameter H1 The sensor selections are as follows The outlet sensor regulates the firing rate based on the outlet water temperature of the unit and the inlet sensor regulates the firing rate based on the inlet water temperature of the unit If the outlet sensor is selected and the optional system supply sensor is connected the control will regulate the firing rate based on the system sensor temperature If the inlet sensor is selected and the optional system return sensor is connected the control will regulate the firing rate based on the system return sensor The default sensor is the Outlet Sensor H2 Enable input active inactive The boiler or water heater can receive a call for heat in two different ways First an external contact like a tank thermostat or sensor like a tank sensor can ge
48. joj ojojoj ojoljojoljoljojoljojog oj ojJ od o oJ o xXIxizixixizizizizizizizizis amp isxizizizizizizizizizizizixixlizizizizi ixixixixix i GENERAL SETTINGS TEMPERATURE 0 N NIN 5 T NIN ak N Low Outdoor Temperature High Outdoor Temperature Setpoint at Low Outdoor Temperature Setpoint at High Outdoor Temperature utdoor Shutdown Setpoint utdoor Shutdown Differential Shfit Reset Curve oost Temperature Boost Time OJO a 2 2 2 2 2 2 2 00 OUTDOOR RESET DHW SETTINGS FUNCTIONS LOGGING 13 Copper fin Boiler Water Heater and Pool Service Manual 1 Service Parameter table continued Table 1D continued from previous page This table lisss SMART SYSTEM control module parameters and where to access them D ti See Installer Access escription P Page A Modify Display Modify 1 Anti cycle Delay 19 No No Ys Yes 7s WmomofTmeSmgs13 9 No Ne ves Yes a boty semeen saos 13 f no ne f ves os ena pu eases Yes s Ems Input Reve 20 No no ve ves IM EE C Wee CR RAT 5 Sequencer 20 No No Yes Yes s Modbus Active ade 20 No no ves ves esie fat No e j ves J ANTI CYCLING 2 Vvotage
49. k 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 120 VAC input to the main control board has Check 120 VAC supply to the transformer dropped below 100 VAC Check wiring connections at the low voltage terminal strip Low Voltage Check the wire size length to remote devices Replace the main control board 41 Copper fin Boiler Water Heater and Pool Service Manual 3 Troubleshooting Table 3E continued from previous page Troubleshooting Chart Fault Messages Displayed on Operator Interface FAULT DESCRIPTION CORRECTIVE ACTION The main control board has detected Cycle main power internal fault Watch Dog Error Replace the main control board The main control board has detected an Cycle main power Replace the main control board The main control board has detected Cycle main power Program EEProm internal fault Replace the main control board Cycle main power The main control board has detected Replace the main control board internal fault Restore default parameters using the PC program Press RESET The main control board has detected an No Error Stored internal fault
50. l 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 o 4000 158 25000 176 249 0 22 1 816 1 344 Temperature Resistance Resistance f Temperature Resistance Resistance 158 158 176 176 194 194 212 212 so ise me we 14 sae a jm sns 29 104 am ses a vu O o ame d 1 3 Table 3C Outdoor Air Sensor Resistance vs Temperature wv mem o a cmm 9 ooo Pes 33 Copper fin Boiler Water Heater and Pool Service Manual 3 Troubleshooting Table 3D Troubleshooting Chart Noisy System FAULT CAUSE CORRECTIVE ACTION Gas supply problem Refer to the 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 27 and 28 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 Dir
51. led 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 25 Copper fin Boiler Water Heater and Pool Service Manual 2 Maintenance 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 loca
52. mp 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 pump Replace the main control board External control is cycling too often Check set point of the external control Check the wiring between the external control and Rem Ctrl Fit the unit Replace the control EI 40 E Copper fin Boiler Water Heater and Pool Service Manual 3 Troubleshooting continued Table 3E continued from previous page Troubleshooting Chart Fault Messages Displayed on Operator Interface FAULT DESCRIPTION CORRECTIVE ACTION After downloading parameters from a laptop Press the ENTER RESET button on the Smart Parameters the main control board must be reset System display panel Progr Will require a manual reset once the condition has been corrected Press the RESET button on the SMART SYSTEM display to reset While the unit is in Service Mode the outlet e Establish a heating load to remove heat from the temperature has exceeded 185 F 85 C 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 system Refer to the Water Connections Section of the Installation and Operation Manual for the proper piping methods Service Blk Chec
53. n board and the main control board Connect the harness at both points Blown tuse Replace fuse F6 on the main control board see FIG 3 1 on page 31 of this manual Bad display board Replace board Bad main control board Replace main control board Main control board temperature set point Review temperature setting satisfied j Remote thermostat satisfied e Review remote thermostat setting temperature above Warm Check location of outside air sensor Check Weather Shutdown WWSD set point for resistance of outdoor air sensor and compare to Table main control board 3D on page 33 of this manual No Burner Operation Outside air e Consult display for specific fault Refer to fault descriptions on pages 35 42 of this manual for corrective actions Unit locked out on fault Ramp delay active e Check ramp delay parameter settings Optional PC software required e Turn ramp delay feature off See page 18 of this Unit Does Not manual for instructions on how to turn this feature off Modulate to 100 Boiler controlled by BMS Outlet temperature too high e Check BMS parameter settings Optional PC software required Delta T too high 32 Copper fin Boiler Water Heater and Pool 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 al
54. ne by setting the Cascade to Active This setting is adjustable by the installer by accessing parameter H4 The default value is Inactive H5 Sequencer active inactive boiler only The individual stages in the heater can be controlled separately with an external sequencer This setting is adjustable by the installer by accessing parameter H5 H6 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 H6 must be set to ACTIVE The default value is Inactive H7 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 H7 The range of this parameter is 0 to 120 seconds The default value is 10 seconds Copper fin Boiler Water Heater and Pool Service Manual 1 Service continued I Cascade I1 Cascade address The boiler designated as the Leader needs to be programmed with address 0 All the Member boilers require addresses from 1 to 7 and the addresses must be different for each Member The a
55. nerate a call for heat Second the 0 10Vdc voltage from BMS can be used to generate the call for heat as well as provide the set point or modulation level On boilers the external contact is connected to the Stage 1 input on the low voltage connection board On water heaters the external contact is connected to the Tank Thermostat input on the low voltage connection board When a tank sensor is connected the Tank Thermostat input is not used When the call for heat comes from an external contact or tank sensor the enable input must be set to active When the call for heat comes from the 0 10Vdc input the enable input must be set to inactive This setting is adjustable by the installer by accessing parameter H2 The default setting is Active 20 TIME j MINUTES TIME 5 4 6 H3 BMS input active inactive When the building management input is enabled the control modulates the unit or the cascade based on the voltage on the 0 10V input on the connection board The 0 10V input may control either the modulation of the unit s or the set point This setting is adjustable by the installer by accessing parameter H3 The default value is Inactive See menu Section J to adjust the parameters that control the BMS operation H4 Cascade active inactive Boilers or water 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 do
56. nt kits are available from your distributor When at IV ven m i A CAUTION a Category vent syste s 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 Copper fin Boiler Water Heate
57. old 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 Repeatthe 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 Turnon the appliance and test fire the unit 7 Repeat this process with each gas valve Copper fin Boiler Water Heater and Pool Service Manual 2 Maintenance continued Figure 2 4 Measuring manifold gas pressure PRESSURE REGULATOR ADJUSTMENT UNDER SCREW r CHAMBER PRESSURE as INLET OUTLET MANOMETER GAS TO BARBED VALVE FITTING CONTROL KNOB TABLE 2B Net Manifold Pressure Regulator Pressure Less Front Chamber Pressure MODEL 402 752 992 2072 29 Copper fin Boiler Water Heater and Pool 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 shutof
58. prevent the control module or other components from operating Turn OFF the power to the appliance at the external line switch Remove front access cover Inspect fuses F2 F4 F5 and F6 see FIG 3 1 below Figure 3 1 Control Module Fuses F6 5 AMPS F4 5 AMPS A F5 5 AMPS LJ J LJ J F2 3 15 AMPS The appliance is shipped with four 4 spare fuses in a plastic bag attached to the control panel 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 A 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 Install front access cover after fuse inspection Restore power to the appliance at the external line switch and verify boiler water heater operation Start up Section in the Installation and Operation Manual after completing boiler water heater service 31 Copper fin Boiler Water Heater and Pool Service Manual 3 Troubleshooting Table 3A Troubleshooting Chart No Display Check external line switch fuse or breaker Check position of ON OFF switch Turn switch to the No 120 VAC supplied to unit ON position Check 120 VAC through the ON OFF switch voltage through switch replace switch Check wiring harness connection between the display No Display Bad wiring connectio
59. r and Pool 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 10 Reassemble in reverse order 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 enterin
60. r sensor is installed the control will calculate the water temperature set point based on the outdoor air temperature As the outdoor air temperature drops the water temperature set point increases This feature allows the unit to be more efficient in periods of mild weather see FIG 1 1 on page 17 F1 Minimum air temperature When the outdoor air temperature drops to this point the water temperature will be at its maximum setting FIG 1 1 The set point will continue to increase as the outdoor temperature drops below this setting The water temperature will be limited by the user set point This parameter can be changed by the installer by accessing parameter Fl The temperature range of this parameter is 22 F 30 C to 86 F 30 C The default value is 25 F 4 C F2 Maximum air temperature When the outdoor air temperature rises to or above this point the water temperature will be at its minimum setting FIG 1 1 This parameter can be changed by the installer by accessing parameter F2 The temperature range of this parameter is 22 F 30 C to 86 F 30 C The default value is 70 F 21 C 18 Default 70 F OUTDOOR OUTDOOR AIR TEMPERATURE AT MINIMUM RESET F3 Maximum SH set point When the outdoor temperature drops to its minimum setting F1 the water temperature set point will be at this value if the SH set point is set higher FIG 1 1 This parameter can be changed by the installer by
61. re must go above set point before the lead boiler will turn off This parameter can be adjusted by the installer by accessing parameter I3 The temperature range for this parameter is 0 F 0 C 54 F 30 The default value is 9 9 F 5 C 14 Cascade differential boilers only This parameter determines how much the temperature must go below the turn off temperature Set point Offset before the lead boiler turns on This parameter can be adjusted by the installer by accessing parameter I4 The temperature range for this parameter is 0 F 0 C 54 F 30 C The default value is 19 8 F 11 C J Building Management System BMS J1 BMS type When the unit or cascade is controlled by the 0 10V BMS input the voltage signal can control either the firing rate power or the set point This parameter may be adjusted by the installer by accessing parameter J1 The default value is Power J2 Voltage at minimum This setting determines the voltage at which the external signal begins to increase either the modulation or the set point Below this voltage the modulation or set point will be at their minimum values This parameter can be adjusted by the installer by accessing parameter J2 The range for this parameter is OV J3 0 1V The default value is 2V J3 Voltage at maximum This setting determines the voltage at which the external signal forces either the modulation or the set point to their maximum value This p
62. rvice Manual 3 Troubleshooting A 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 FAEN Never jumper bypass any device except A WARNING 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 Make sure thermostat is calling for heat and contacts including appropriate zone controls are closed Check for 24 VAC between thermostat wire nuts and ground 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 Gas pressures Refer to the Gas Connections Section of the Installation and Operation Manual for detailed information concerning the gas supply Check control module fuses NOTICE ALWAYS check control module fuses before replacing control module or any major components blower etc If one of these fuses is blown it can
63. 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 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 2 3 4
64. structions reset Press the RESET button on the SMART Inspect the burners Reference pages 26 and 27 SYSTEM display to reset of this manual for removal and cleaning procedures Replace if necessary Refer to the Checking Manifold Gas Pressure and Combustion Analysis Procedure on pages 27 and 28 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 Replace the wiring or the main control board as necessary Amp draw of the hot surface igniter did not Measure the amp draw of the hot surface igniter during meet the minimum requirement of 2 6 amps the trial for ignition stage If less than 2 6 amps reset once the condition replace the hot surface igniter has been corrected Press the RESET button on the f more than 2 6 amps replace the control module SMART SYSTEM display to reset Flame CKT The main control board has detected an Replace the main control board internal fault Error 36 E Copper fin Boiler Water Heater and Pool Service Manual 3 Troubleshooting continued Table 3E continued from previous page Troubleshooting Chart Fault Messages Displayed on Operator Interface The unit was running and lost the flame signal No Flame Running Will require a manual reset once the condition has been corrected Press the RESE
65. t rise too high Excessive pressure rise indicates expansion tank sizing or performance problem 4 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 Check expansion tank if provided 1 Expansion tanks provide space for water to move in and out as the heating system water expands due to temperature increase or contracts as the water cools Tanks may be open closed diaphragm or bladder type See the Water Connections Section of the Installation and Operation Manual for suggested best location of expansion tanks and air eliminators Copper fin Boiler Water Heater and Pool 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 A WARNING 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 corro
66. ted on either end of the appliance A WARNING The area around the burner viewport is hot and direct contact could result in burns Figure 2 1 Flame Pattern Illustration G NORMAL YELLOW TIP _ YELLOW FLAME FLAME LIFT Normal Flame A normal flame at 10096 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 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 26 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 gaskets sealants on disassembled components or jacket panels must be replaced with new gaskets sealants on reassembly Gasket and seala
67. than 0 F the night setback feature becomes active This will require start and stop times to be programmed for the days that reduced temperatures are required These times can be changed by the user or the installer by accessing parameter A6 Each day of the week Monday through Sunday will have an on and off time Example Monday ON 22 30 Tuesday OFF 6 45 If you wish to skip a day and have no night setback set the on and off times to the same time and prior to 12 00 p m To keep night setback active through the entire day set the on and off time to the same time and after 12 00 p m The default times for each day will be 08 00 OFF and 18 00 ON A7 DHW Night setback offset Once the internal clock has been set correctly the DHW night setback feature can be used to program a lower SH set point during various times of the week The value of this parameter will be subtracted from the normal set point to determine the set point used during night setback This parameter can be changed by the user or installer by accessing parameter A7 The temperature range for this parameter is O F to 90 F 50 The default value is O F A8 DHW Night setback times If parameter A7 is set to anything other than 0 F the DHW night setback feature becomes active This will require start and stop times to be programmed for the days that reduced temperatures are required These times can be changed by the user or the installer by accessing param
68. that are important but not related to personal injury or property damage NOTICE Copper fin Boiler Water Heater and Pool Service Manual Please read before proceeding A WARNING Installer Read all instructions including this manual and the Installation and Operation Manual before Perform steps in the order given installing 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 NOTICE 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
69. 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 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
70. ty damaged burner Refer to pages 26 and 27 in this manual for the burner Noisy removal and inspection procedure Clean or replace the Operation burner as necessary 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 Replace relay No Pump Operation Faulty pump Replace pump Boiler Pump SEC eye Internal fault on control board e Check fuse F5 or DHW Pump e Replace main control board Note Make sure the boiler pump horse power hp does not exceed 1 hp System pressure exceeds relief valve Lower the system pressure below the rating of setting the supplied relief valve or replace the standard relief valve with a higher rated valve up to the maximum pressure of the heat exchanger Relief Valve Improperly sized expansion tank Install properly sized expansion tank Opening Outlet water temperature in excess of 210 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
71. urface 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 A WARNING 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 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 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 reinstal
72. ust 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 DHW settings E1 DHW tank set point When a temperature sensor is installed in the DHW tank the DHW tank set point sets the target temperature of the water in the tank The user or installer can adjust this set point by accessing parameter El The temperature range of this parameter is 60 F 15 to 190 F 88 The default value is 120 F 49 E2 DHW boiler set point boiler only Whenan indirect DHW call for heat becomes active the control will use the DHW boiler set point to determine the firing rate of the unit based on the actual outlet water temperature This parameter can be changed by the installer by accessing parameter E2 The temperature range of this parameter is 32 F 0 C to 261 F 127 C The default value is 180 F 82 E3 SH DHW switching time boiler only When a SH call for heat and a DHW call for heat are present at the same time the SMART SYSTEM control can switch back and forth between the two calls The time that the control services the SH demand before switching to the DHW demand can be adjusted by using parameter E3 The range of this parameter is 0 to 240 minutes Setting this parameter to 0 disables the switching function The control will service the DHW demand until it ends
73. y Once a SH demand has been satisfied a set amount of time must elapse before the control will respond to a new SH 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 G2 This parameter can be changed by the installer by accessing parameter G1 The time range for this parameter is 0 minutes to 40 minutes The default value is 1 minute G2 Anti cycle override differential The control will bypass the anti cycling time if the inlet water temperature drops too quickly 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 G2 The temperature range of this parameter is 0 F 0 C to 54 F 30 C The default value is 10 F 5 C G3 Minimum on off stages 1 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 G3 The range of this parameter is 0 to 255 seconds The default value is 60 seconds G4 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
74. y 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 399 999 750 000 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

Lochinvar 402 - 2072 Patio Heater User Manual

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