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Lochinvar 402 - 2072 Service Manual

44 pages1.65 Mb

2Hazard definitions
Contents
- DANGER WARNING CAUTION CAUTION NOTICE
- Copper-fin II/IIE Boiler and Water Heater
3Please read before proceeding
- When servicing appliance
- Appliance operation
- Appliance water
- Handling ceramic fiber materials
  - REMOVAL OF COMBUSTION CHAMBER LINING
  - NIOSH stated First Aid.
4What is in this manual?
- Service
  - The Copper-fin display
  - Control module inputs
  - Control module outputs
  - General
  - Control panel menu access
  - Control panel parameter access
  - Quick start information -- parameter tables
- Maintenance
- Troubleshooting
  - Copper-fin boiler operation
  - Copper-fin water heater operation
- 5The Copper-fin display
  - MENU/EXIT DISPLAY SCREEN ENTER/RESET
  - TXENSUOIVERPNWODPU
- 6Control inputs
- 7Control outputs
- 8General Operation
  - How the appliance operates
  - How the control module operates
  - Sequence of operation
  - Saving parameters
- 10Sequence of operation
- 11Display panel menu access
- 13Parameter table A - Boiler Operation
  - TEMPERATURE
  - F
  - E
  - D
  - C
  - B
  - A
- 14Parameter table A - Boiler Operation
  - L
  - K
  - J
  - I
  - H
  - G
- 15Parameter table B - Water Heater Operation
  - H
  - G
  - F
  - E
  - D
  - A
  - B C
- 16Parameter table B - Water Heater Operation
  - I
  - J K
- 17Viewable and changeable control parameters
  - Copper-fin II/IIE Boiler and Water Heater
    - General
    - Temperature settings
  - NOTICE
    - 18Data logging
    - Functions
    - 19DHW settings
    - 20Outdoor air reset (boiler only)
    - 21Anti-cycling
    - 22Control modes
    - 23Cascade
    - Building Management System (BMS)
    - 24Service Notification
    - Circulation pumps
25Maintenance and annual startup Service technician
Owner maintenance
- 26Address reported problems
- Inspect appliance area
- Check all piping for leaks
- Inspect appliance interior
- Flue vent system and air piping
- Combustion air filter
- Check water system
- Check expansion tank (if provided)
- 27Check relief valve
- Inspect/replace hot surface igniter
- Inspect/replace hot surface igniters
- 28Check all wiring
- Check control settings
- Check burner flame
- Perform start-up and checks
- Check flue gas passageways
- Inspect and clean burner
- 29Checking combustion air pressure
- 30Adjusting combustion air pressure
- Checking manifold gas pressure
- 32Inspect and clean the heat exchanger
- Review with owner
- Oiled bearing circulators
- 33Before troubleshooting:
- Check the following:
- Check control module fuses
  - 34FAULT CAUSE CORRECTIVE ACTION
  - Copper-fin II/IIE Boiler and Water Heater
    - Table 3A Troubleshooting Chart - No Display
    - No Display
    - No Burner Operation
    - Unit Does Not Stage to 100%
- Checking temperature sensors
- 35S1a Inlet/Outlet/System/Tank
  - 36FAULT CAUSE CORRECTIVE ACTION
  - Copper-fin II/IIE Boiler and Water Heater
    - 37Gas Pressure SW
    - Table 3E Troubleshooting Chart - Fault Messages Displayed on Operator Interface
    - Flow Switch/ LWCO
    - Anti-cycling
    - Flame Sequence
    - 38No Flame Ign
    - HSI Current Low
    - Flame CKT Error
    - 39No Flame Running
    - Auto Reset High Limit
    - 40Inlet Low
    - Sensor Open
    - Sensor Shorted
    - 41Louver Proving
    - Tank Open
    - APS Open
    - APS Closed
    - Wrong ID Plug
    - 42Temp O/Shoot
    - Rem Ctrl Flt
    - Parameters Progr
    - 43Service Blk
    - Low Voltage
    - Watch Dog Error
    - Write EEProm
    - Program EEProm
    - CRC Parameters
    - No Error Stored

44 pages1.64 Mb

2Hazard definitions
Contents
- DANGER WARNING CAUTION CAUTION NOTICE
- Copper-fin II/IIE Boiler, Water Heater and Pool
3Please read before proceeding
- When servicing appliance
- Appliance operation
- Appliance water
- Handling ceramic fiber materials
  - REMOVAL OF COMBUSTION CHAMBER LINING
  - NIOSH stated First Aid.
4What is in this manual?
- Service
  - The Copper-fin display
  - Control module inputs
  - Control module outputs
  - General
  - Control panel menu access
  - Control panel parameter access
  - Quick start information -- parameter table
  - Copper-fin operation
- Maintenance
- Troubleshooting
- 5The Copper-fin display
  - MENU/EXIT DISPLAY SCREEN ENTER/RESET
  - TXENSUOIVERPNWODPU
- 6Control inputs
- 7Control outputs
- 8General Operation
  - How the appliance operates
  - How the control module operates
  - Sequence of operation
  - Saving parameters
- 10Sequence of operation
- 11Display panel menu access
- 13Parameter table
  - Table 1D_This table lists SMART SYSTEM control module parameters and where to access them
    - TEMPERATURE
  - F
  - E
  - D
  - C
  - B
  - A
- 14Parameter table
  - L
  - K
  - J
  - I
  - H
  - G
- 15Viewable and changeable control parameters
  - Copper-fin II/IIE Boiler, Water Heater and Pool
    - A: General
    - B: Temperature settings (boiler only)
  - NOTICE
    - 16C: Data logging
    - D: Functions
    - 17E: DHW settings
    - 18F: Outdoor air reset (boiler only)
    - 19G: Anti-cycling
    - 20H: Control modes
    - 21I: Cascade
    - J: Building Management System (BMS)
    - 22L: Service Notification
    - K: Circulation pumps
23Maintenance and annual startup Service technician
Owner maintenance
- 24Address reported problems
- Inspect appliance area
- Check all piping for leaks
- Inspect appliance interior
- Flue vent system and air piping
- Combustion air filter
- Check water system
- Check expansion tank (if provided)
- 25Check relief valve
- Inspect/replace hot surface igniter
- Inspect/replace hot surface igniters
- 26Check all wiring
- Check control settings
- Check burner flame
- Perform start-up and checks
- Check flue gas passageways
- Inspect and clean burner
- 27Checking combustion air pressure
- 28Adjusting combustion air pressure
- Checking manifold gas pressure
- 30Inspect and clean the heat exchanger
- Review with owner
- Oiled bearing circulators
- 31Before troubleshooting:
- Check the following:
- Check control module fuses
  - 32FAULT CAUSE CORRECTIVE ACTION
  - Copper-fin II/IIE Boiler, Water Heater and Pool
    - Table 3A Troubleshooting Chart - No Display
    - No Display
    - No Burner Operation
    - Unit Does Not Modulate to 100%
- Checking temperature sensors
- 33S1a
  - 34FAULT CAUSE CORRECTIVE ACTION
  - Copper-fin II/IIE Boiler, Water Heater and Pool
    - 35Gas Pressure SW
    - Table 3E Troubleshooting Chart - Fault Messages Displayed on Operator Interface
    - Flow Switch/ LWCO
    - Anti-cycling
    - Flame Sequence
    - 36No Flame Ign
    - HSI Current Low
    - Flame CKT Error
    - 37No Flame Running
    - Auto Reset High Limit
    - 38Inlet Low
    - Sensor Open
    - Sensor Shorted
    - 39Louver Proving
    - Tank Open
    - APS Open
    - APS Closed
    - Wrong ID Plug
    - 40Temp O/Shoot
    - Rem Ctrl Flt
    - 41Parameters Progr
    - Service Blk
    - Low Voltage

44 pages1.64 Mb

2Hazard definitions
Contents
- DANGER WARNING CAUTION CAUTION NOTICE
- Copper-fin II/IIE Boiler, Water Heater and Pool
3Please read before proceeding
- When servicing appliance
- Appliance operation
- Appliance water
- Handling ceramic fiber materials
  - REMOVAL OF COMBUSTION CHAMBER LINING
  - NIOSH stated First Aid.
4What is in this manual?
- Service
  - The Copper-fin display
  - Control module inputs
  - Control module outputs
  - General
  - Control panel menu access
  - Control panel parameter access
  - Quick start information -- parameter table
  - Copper-fin operation
- Maintenance
- Troubleshooting
- 5The Copper-fin display
  - MENU/EXIT DISPLAY SCREEN ENTER/RESET
  - TXENSUOIVERPNWODPU
- 6Control inputs
- 7Control outputs
- 8General Operation
  - How the appliance operates
  - How the control module operates
  - Sequence of operation
  - Saving parameters
- 10Sequence of operation
- 11Display panel menu access
- 13Parameter table
  - Table 1D_This table lists SMART SYSTEM control module parameters and where to access them
    - TEMPERATURE
  - F
  - E
  - D
  - C
  - B
  - A
- 14Parameter table
  - L
  - K
  - J
  - I
  - H
  - G
- 15Viewable and changeable control parameters
  - Copper-fin II/IIE Boiler, Water Heater and Pool
    - A: General
    - B: Temperature settings (boiler only)
  - NOTICE
    - 16C: Data logging
    - D: Functions
    - 17E: DHW settings
    - 18F: Outdoor air reset (boiler only)
    - 19G: Anti-cycling
    - 20H: Control modes
    - 21I: Cascade
    - J: Building Management System (BMS)
    - 22L: Service Notification
    - K: Circulation pumps
23Maintenance and annual startup Service technician
Owner maintenance
- 24Address reported problems
- Inspect appliance area
- Check all piping for leaks
- Inspect appliance interior
- Flue vent system and air piping
- Combustion air filter
- Check water system
- Check expansion tank (if provided)
- 25Check relief valve
- Inspect/replace hot surface igniter
- Inspect/replace hot surface igniters
- 26Check all wiring
- Check control settings
- Check burner flame
- Perform start-up and checks
- Check flue gas passageways
- Inspect and clean burner
- 27Checking combustion air pressure
- 28Adjusting combustion air pressure
- Checking manifold gas pressure
- 30Inspect and clean the heat exchanger
- Review with owner
- Oiled bearing circulators
- 31Before troubleshooting:
- Check the following:
- Check control module fuses
  - 32FAULT CAUSE CORRECTIVE ACTION
  - Copper-fin II/IIE Boiler, Water Heater and Pool
    - Table 3A Troubleshooting Chart - No Display
    - No Display
    - No Burner Operation
    - Unit Does Not Modulate to 100%
- Checking temperature sensors
- 33S1a Inlet/Outlet/System/Tank
  - 34FAULT CAUSE CORRECTIVE ACTION
  - Copper-fin II/IIE Boiler, Water Heater and Pool
    - 35Gas Pressure SW
    - Table 3E Troubleshooting Chart - Fault Messages Displayed on Operator Interface
    - Flow Switch/ LWCO
    - Anti-cycling
    - Flame Sequence
    - 36No Flame Ign
    - HSI Current Low
    - Flame CKT Error
    - 37No Flame Running
    - Auto Reset High Limit
    - 38Inlet Low
    - Sensor Open
    - Sensor Shorted
    - 39Louver Proving
    - Tank Open
    - APS Open
    - APS Closed
    - Wrong ID Plug
    - 40Temp O/Shoot
    - Rem Ctrl Flt
    - 41Parameters Progr
    - Service Blk
    - Low Voltage

Also you can find more Lochinvar manuals or manuals for other Household Appliance.

Lochinvar 402 - 2072 Operation Manual

80 pages7.61 Mb

Installation & Operation Manual Models: 402 - 2072
- 2Contents
- Hazard definitions
  - DANGER WARNING CAUTION CAUTION NOTICE
- 3Please read before proceeding
  - Warranty
  - Checking equipment
  - Special instructions
- 4Please read before proceeding
  - Codes
  - Owner warning
  - Prevention of freezing
  - Safety information
- 6The Copper-fin II - How it works...
- 7The Copper-fin II - How it works... (continued)
  - Models 992 - 2072 Left Side (inside unit) Models 992 - 2072 Right Side (inside unit)
  - Models 992 - 2072 Rear View Models 992 - 2072 Front View
- 8Ratings
  - Copper-fin II I=B=R Rating
  - Other Specifications
  - 9
    - Location of unit
    - Freeze protection
  - TABLE - 1A
    - Indoor clearances from combustible construction
    - 10Combustion and ventilation air
    - Combustion air options
    - Location
    - Outdoor boiler installation
    - Hydronic systems anti-freeze
111
- 12
- BEFORE YOU BEGIN
  - Identify your appliances vent system:
  - Venting Category Definitions:
  - CAT IV Flue pipe materials
13A B C
- Vent system options:
14A
B
C
- TABLE - 2A
- 15General information
  - Venting support
  - Barometric damper location
16A
- Negative draft
- 17Vertical vent termination clearances and location
192
- Length of air inlet pipe
- Sidewall air inlet
- Combustion air inlet piping
- Vertical DirectAire venting -
B
- 20Vertical Rooftop Air Inlet
- Combined air inlet points
- 21
- TABLE - 2B
222
- Sidewall venting
C
- 24
- TABLE - 2C
- 25Horizontal DirectAire venting (Powered Venting)
  - Venting of flue products
  - TABLE - 2D
    - Flue outlet piping
- 26Direct venting - see page 14.
  - Vertical DV venting termination
  - 27
    - Horizontal DV venting termination
  - TABLE - 2E
    - 28Air inlet piping materials
    - 29Vertical and sidewall combustion air inlet
- 30Outdoor installation
  - Outdoor vent/air inlet location
  - TABLE - 2F
    - The outdoor vent cap kit
313
- Connecting to gas supply
  - TABLE 3A INLET GAS PRESSURE
- Gas pressure test
- Gas piping
- Gas connection
323
- TABLE - 3C
- TABLE 3B
  - Gas train and controls
- Combination gas valves
  - Venting of combination gas valves
333
- Checking gas supply pressure
- TABLE - 3D
- 34Heat exchanger
- Inlet and outlet connections
- Water flow switch
- Low water cutoff
  - Initial set-up of maximum water flow
- 35Relief valve
- Heating boiler installations
  - Piping of the boiler system
  - Boiler circulator requirements
  - Water connections (heating boilers only)
  - 36
    - Low Temperature Return Water Systems
  - TABLE 4A
    - Low temperature bypass requirements
    - Minimum boiler water temperatures
  - 37
    - Three way valves in system
    - Radiant floor and snow melt heating systems
  - TABLE - 4B
    - Low system water volume
  - 38
  - TABLE - 4D
    - Boiler bypass requirements
  - TABLE - 4C
    - Temperature / pressure gauge
    - Typical heating boiler installations
    - Installation with a chilled water system
    - DHW installation
  - - Boiler operating control module
  - TABLE - 5A
- 43Installation must comply with:
  - 44Line voltage connections
  - Low voltage connections
  - EMS or remote thermostat connection
  - DHW (Domestic Hot Water) thermostat
  - DHW tank sensor
455
- Louver relay
- Louver proving switch
- System supply sensor (recommended use)
- System return sensor
- Boiler Management System (BMS)
- Runtime contacts
- 3-way valve out
- 0 - 10V rate out
- 0 - 10V system pump in
- Sequencer
- Alarm contacts
- 46Wiring of the cascade
- 47Check/control water chemistry
- Freeze protection (when used)
- Fill and test water system
- Purge air from water system
- Check for gas leaks
- 48Check thermostat circuit(s)
- Check vent and air piping
- Placing the boiler in operation
- Start the boiler
- If boiler does not start correctly
- Set space heating operation (boiler only)
496
- Figure 6-1_Lighting Instructions
- FOR YOUR SAFETY READ BEFORE OPERATING
- WARNING:
  - OPERATING INSTRUCTIONS
  - TO TURN OFF GAS TO APPLIANCE
  - 50
    - Set DHW operation
  - NOTICE
  - 51General
    - How the appliance operates
    - - How the control module operates
      - Control inputs and outputs
      - 52Temperature control
      - Protection features
      - 53Boiler temperature regulation
      - Outdoor reset operation, if used (boilers only)
      - Cascade
  - 55Sequence of operation
    - OPERATION DISPLAY
  - 56Copper-fin II control module
    - Figure 7-1_Control Panel - Operator Interface
      - MENU/EXIT DISPLAY SCREEN ENTER/RESET
      - TXENSUOIVERPNWODPU
    - 57Access modes
    - Saving parameters
  - 58Status display screens
    - Status Display Screens
    - Screen # Display Shows Description
    - Screen #1 Line 1
    - Screen #1 Line 2
    - 62
    - - Initial set-up of maximum water flow
    - TABLE - 8A
    - TABLE - 8B
      - 63Water chemistry
    - 68
      - Pump operation
    - TABLE D
      - Heat exchanger
    - TABLE 8C
    - 7 8
      - 69Minimum water temperatures (domestic hot water use)
      - Thermostat adjustment procedure
    - 70
      - Optional adjustable auxiliary high water temperature limit control
      - Optional relief valve
      - Thermal expansion
      - Cathodic protection
  - 71Maintenance and annual startup Service technician
  - Owner maintenance
    - 72Address reported problems
    - Inspect appliance area
    - Check all piping for leaks
    - Inspect appliance interior
    - Flue vent system and air piping
    - Check water system
    - Check expansion tank
    - Check relief valve
    - Inspect/replace hot surface igniter
    - Check all wiring
    - Check control settings
739
- Ignition system checkout
- 74Check burner flame
- Perform start-up and checks
- Check flue gas passageways
- Inspect and clean burner
- 75Inspect and clean the heat exchanger
- Review with owner
- Oiled bearing circulators
7610
- NEUTRAL
- 120VAC COIL
- PUMP RELAY
- UNIT PUMP
- SYSTEM PUMP RELAY COIL
- 120V
- IND-DHW PUMP RELAY COIL
- LINE
- CONT
  - 24V COM
- R
  - DISPLAY
    - INLET SENSOR
    - SAFETY OUTLET SENSOR
    - ON/OFF SWITCH
    - CHASSIS
    - 60VA 3
    - 1BK W32
    - Y BL
    - CONTROLLER XFMR
    - DIGITAL HARNES
    - S
    - 24V
    - OPT. ALARM HARNESS
    - R R
    - 1HP MAX
      - 120V
      - 120V/60Hz SUPPLY
      - LOW VOLT HARNE
      - S
      - MAIN POWER HARNESS OPT. MODBUS HARNESS CKT. BREAKER
      - 10K/20K
      - 20K
7710
- G
- MODBUS ADAPTER
- GBK
- 3
- BK
- 3W
- BURNER BURNER
- LBL20082 REV A
- .
- MAIN UNIT HARNESS
- HI-LIMIT
- LO - GAS
- 2
- 4
- 6
- 5
- 3
- NOTE: NUMBER OF GAS VALVES VARIES BY MODEL
- PLAY
- S
  - GROUND
- CONTROLLER
  - CONSULT FACTORY
  - ITAL HARNESS
  - W
  - FLOW SWITCH
  - FLOW SWITCH
  - GROUNDHSI
  - #1
  - CHASSIS GROUND
  - LWCO 24VAC
  - RESET
  - LWCO PROBE
  - TEST
  - AIR PROVE SWTICH
  - BLOCK FLUE SWITCH
  - HSI#2
  - CIRCUIT BREAKER
- DANGER
- !
  - 2-SPD BLOWER
  - 50VA 60VA 75VA 100VA
  - HI-GAS
  - OPT. ALARM LOW VOLTAGE HARNESS
  - CONNECTION BOARD
  - VOLT HARNESS
  - LOW VOLT HARNESS
  - DIGITAL HARNESS
  - 2 W
7811
- BOX DEPICTS OPTIONAL ITEMS
- 120 VAC
- LOW VOLTAGE
7911
- ((
- LBL20083 REV B
  - (
  - ((

Also you can find more Lochinvar manuals or manuals for other Household Appliance.