Lochinvar 402 - 2072 manual

Copper-fin II/IIE Boiler , W ater Heater and Pool Heater Service Manual Models: 402 - 2072 (Boiler & W ater 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. Perfo[...]

2 Hazard definitions The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk level s or to important information concerning the life of the product.  DANGER  WARNING  CAUTION CAUTION NOTICE DANGER indicates an imminently hazardous situation which, if not avoided, will result[...]

Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual Please read before proceeding Installer – Read all instructions, including this manual and the Installation and Operation Manual, before installing. Perform steps in the order given. User – This manual is for use only by a qualified heating installer/service technician. Refer to the[...]

4 What is in this manual? Service The Copper-fin display • Display panel readout, buttons and their functions Control module inputs • Control module inputs and options Control module outputs • Control module outputs and options General • How the appliance operates • How the control module operates • Access modes -- user and installer ?[...]

1 Service 5 MENU/E XIT DISPLAY SCREEN ENT ER/RE SET T X E N S U O I V E R P N W O D P U • Press to turn heater off or back on • Press to select a menu item • Press after parameter programming to store parameter data • Press to exit Service Mode • Hold 5 seconds to enter code Input Mode (Menu Mode) • Press to move up one level in Menu Mo[...]

1 Service 6 SMAR T SYSTEM CONTROL BOARD LOW VOLTAG E CONNECTI ON BOARD DHW THERMO STAT (OPTIONAL) ROOM T HER MOSTAT/ ZONE CO NTROL (OPTIONAL) SYSTEM SUPP LY/ ENABLE SENSOR (OPTIONAL) SYSTEM RETU RN/ POOL SE NSOR (OPTIONAL ON BOIL ER) (STD ON PO OL HEATER) SEQU ENCER BUIL DIN G MANAGE MENT SYS TEM (FIELD PROVIDED ) OUTDOO R SENS OR (OPTIONAL) LOUVER[...]

7 SMAR T SYSTEM CONTRO L BOARD LOW VOLTAGE CONNECTI ON BOARD THREE W AY VALV E (OPTIONAL ON BOILER ) (STD ON POOL HEATER) LOUVER RELA Y BUILDIN G MANAG EME NT SYSTEM RUN TIME CO NTACT S ALARM CO NTACTS ALARM (OPTIONAL) HEATE R PUM P (BOILER ONLY) SYSTEM PUM P RELA Y DHW P UMP RELA Y (BOILER) DHW PUMP (WATER HEATER) HOT SURFACE IGNITER BLOWER GAS VA[...]

1 Service 8 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 [...]

9 Sequence of operation Table 1A_ Sequence of Operation - Space Heating and DHW 1 Service (continued) OPERATION DISPLAY 1. The manual reset high limit (optional) must be closed before any action will take place. HTR: Standby OUT: 123.8F(129) 2. Upon a call for heat the control turns on the appropriate pumps (system and boiler pumps for space heatin[...]

1 Service 10 Sequence of operation Table 1A_ (continued from previous page) Sequence of Operation - Space Heating and DHW OPERATION DISPLAY 9. If the DHW thermostat remains on for more than 30 minutes, and the space heating call for heat is also on, then the control will turn on the boiler pump, turn off the DHW pump after 2 seconds, and resume fir[...]

11 Display panel menu access Table 1B_ Use this procedure to access menus from the display panel 1 Service (continued) Note: Not all menu listings shown above are available on water heaters. Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual[...]

1 Service 12 Display panel parameter access Cascade BMS Table 1C_ This is a typical example of accessing a parameter, shown for parameter K2, SH pump delay Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual[...]

13 Parameter table Table 1D_ This table lists SMART SYSTEM control module parameters and where to access them 1 Service (continued) Menu Sub Item Description See Page User Access Installer Access Display Modify Display Modify A 1 User Code 15 Yes Yes Yes Yes 2 Time and Date 15 Yes Yes Yes Yes 3 Software Version 15 Yes No Yes Yes 4 Temperature Units[...]

1 Service 14 Parameter table (continued) Table 1D_ (continued from previous page) This table lists SMART SYSTEM control module parameters and where to access them Menu Sub Item Description See Page User Access Installer Access Display Modify Display Modify G 1 Anti-cycle Delay 19 No No Yes Yes 2 Anti-cycle Override Differential 19 No No Yes Yes 3 M[...]

15 Viewable and changeable control 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 change[...]

1 Service 16 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 will 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 parame[...]

1 Service (continued) 17 Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual 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 fu[...]

1 Service 18 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 accessing parameter F3 . The temperature range of this parameter is 32°F (0°C) to 248°F (120°C[...]

1 Service (continued) 19 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 th[...]

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[...]

1 Service (continued) 21 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 addresses can be in any order, regardless of the order in which the units are wired together. This parameter[...]

22 K4: System pump mode (boiler only) The system pump can be configured to operate in one of two modes. “CFH” 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. [...]

2 Maintenance 23 Maintenance and annual startup Service technician (see the following pages for instructions) General: • Address reported problems • Inspect interior; clean and vacuum if necessary; • Check for leaks (water, gas, flue, condensate) • Examine venting system • Check system water pressure/system piping/expansion tank • Check[...]

24 Follow the service and maintenance procedures given throughout this manual and in component literature 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 in this manual and component literature could result in severe personal injury, death[...]

2 Maintenance (continued) 25 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. Safety rel[...]

26 2 Maintenance Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual 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 necess[...]

27 2 Maintenance (continued) Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual 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 usi[...]

2 Maintenance 28 Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual 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 factory for high altitude air pressure settings. Upon removal of [...]

2 Maintenance (continued) 29 Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual PRESSUR E REGULA TO R ADJU STMENT (UNDER CAP SCREW ) INLET OUTLET GAS VALVE CONTRO L KNOB MANOME TER MANIFO LD PRESSUR E CHAM BER PRESSURE TEE TO BARBED FITTI NG Figure 2-4_ Measuring manifold gas pressure TABLE 2B Net Manifold Pressure Regulator Pressure Le[...]

2 Maintenance Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual Inspect and clean the heat exchanger 1. Turn off the main electrical power to the appliance. 2. Turn off the main manual gas shutoff 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[...]

3 Troubleshooting 31 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. Never jumper (bypass) any device except for momenta[...]

3 Troubleshooting 32 FAULT CAUSE CORRECTIVE ACTION No Display - No 120 VAC supplied to unit. • Check external line switch, fuse, or breaker. • Check position of ON/OFF switch. Turn switch to the ON position. • Check 120 VAC through the ON/OFF switch. No voltage through switch, replace switch. - Bad wiring connection. • Check wiring harness [...]

3 Troubleshooting (continued) 33 Temperature Resistance Temperature Resistance -50 490,813 20 46,218 -40 336,606 30 34,558 -30 234,196 40 26,099 -20 165,180 50 19,900 -10 118,018 60 15,311 0 85,362 70 11,883 10 62,465 80 9,299 Checking temperature sensors The appliance temperature sensors (inlet water, outlet water, system water, tank water, flue, [...]

3 Troubleshooting 34 FAULT CAUSE CORRECTIVE ACTION Noisy Operation - Gas supply problem. • R e fe r to th e Gas Connections Section of t he 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 a[...]

3 Troubleshooting (continued) 35 FAULT DESCRIPTION CORRECTIVE ACTION Gas Pressure SW (Will require a manual reset once the condition has been corrected.) - Either the optional manual reset low gas pressure switch or the optional manual reset high gas pressure switch tripped. - Models 992 - 2072 (natural gas) - Automatic Reset Low Gas is open. • R[...]

3 Troubleshooting 36 FAULT DESCRIPTION CORRECTIVE ACTION No Flame Ign (Will require a manual reset. Press the RESET button on the SMART SYSTEM display to reset.) The unit has failed to prove burner flame upon ignition. • Inspect igniter and associated wiring for damage and connection. Reference page 25 of this manual for removal and cleaning proc[...]

3 Troubleshooting (continued) 37 FAULT DESCRIPTION CORRECTIVE ACTION No Flam e Running (Will require a manual reset once the condition has been corrected. Press the RESET button on the SMART SYSTEM display to reset.) The unit was running and lost the flame signal. • Inspect igniter and associated wiring for damage and connection. Reference page 2[...]

38 FAULT DESCRIPTION CORRECTIVE ACTION 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 outlet water temperature has exceeded the setting of the adjustable high limit. • Verify setting of adjustable high limit. • Verify that the system is fu[...]

3 Troubleshooting (continued) 39 FAULT DESCRIPTION CORRECTIVE ACTION 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.) An optional remote proving switch is not making. • Check function of remote devices. • [...]

3 Troubleshooting 40 FAULT DESCRIPTION CORRECTIVE ACTION Temp O/Shoot (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.) The temperature rise across the heat exchanger has exceeded the set parameters for the appliance. • Ver[...]

3 Troubleshooting (continued) 41 FAULT DESCRIPTION CORRECTIVE ACTION Parameters Progr (Will require a manual reset once the condition has been corrected. Press the RESET button on the SMART SYSTEM display to reset.) After downloading parameters from a laptop, the main control board must be reset. • Press the ENTER/RESET button on the Smart System[...]

3 Troubleshooting 42 FAULT DESCRIPTION CORRECTIVE ACTION Watch Dog Error The main control board has detected an internal fault. • Cycle main power. • Replace the main control board. Write EEProm The main control board has detected an internal fault. • Cycle main power. • Replace the main control board. Program EEProm The main control board [...]

43 NOTES[...]

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[...]