Lochinvar Patio Heater 402 2072 User Manual
C(F,H,P)X-SER Rev B  
Copper-fin II/IIE  
Boiler, Water Heater  
and Pool Heater  
Service Manual  
Models: 402 - 2072  
(Boiler & Water Heater)  
Models: 502 - 2072  
(Pool Heater)  
This manual must only be used  
by a qualified heating installer  
ƽ WARNING  
/ service technician. Read all  
instructions, including this  
manual and the Installation  
and Operation Manual, before  
installing. Perform steps in the  
order given. Failure to comply  
could result in severe personal  
injury, death, or substantial  
property damage.  
Save this manual for future reference.  
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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.  
When servicing appliance –  
ƽ WARNING  
• To avoid electric shock, disconnect electrical supply  
before performing maintenance.  
• To avoid severe burns, allow appliance to cool before  
performing maintenance.  
User – This manual is for use only by a  
qualified heating installer/service technician.  
Refer to the User’s Information Manual for  
your reference.  
Appliance operation –  
• Do not block flow of combustion or ventilation air to  
the appliance.  
Have this appliance serviced/inspected by a  
qualified service technician at least annually.  
• Should overheating occur or gas supply fail to shut off,  
do not turn off or disconnect electrical supply to  
circulator. Instead, shut off the gas supply at a location  
external to the appliance.  
Failure to comply with the above could  
result in severe personal injury, death or  
substantial property damage.  
• 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.  
When calling or writing about the appliance  
– Please have the appliance model and serial  
number from the appliance’s rating plate.  
NOTICE  
Appliance water –  
Consider piping and installation when  
determining appliance location (see the  
Installation and Operation Manual).  
• 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.  
Any claims for damage or shortage in  
shipment must be filed immediately  
against the transportation company by the  
consignee.  
• 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  
•
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/  
The combustion chamber insulation in this  
appliance contains ceramic fiber material.  
Ceramicfiberscanbeconvertedtocristobalite  
in very high temperature applications.  
The International Agency for Research on  
Cancer (IARC) has concluded, “Crystalline  
silica in the form of quartz or cristobalite  
from occupational sources is carcinogenic  
to humans (Group 1).” Normal operating  
temperatures in this appliance are below the  
level to convert ceramic fibers to cristobalite.  
Abnormal operating conditions would have  
to be created to convert the ceramic fibers in  
this appliance to cristobalite.  
ƽ WARNING  
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.  
Apply enough water to the combustion chamber lining to  
prevent airborne dust.  
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.  
Remove the combustion chamber lining from the appliance  
and place it in a plastic bag for disposal.  
Wash potentially contaminated clothes separately from  
other clothing. Rinse clothes washer thoroughly.  
NIOSH stated First Aid.  
Avoid breathing dust and contact with  
Eye: Irrigate immediately.  
skin and eyes.  
3
Breathing: Fresh air.  
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Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual  
What is in this manual?  
Maintenance  
Service  
• 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  
The Copper-fin display  
• Display panel readout, buttons and their functions  
Control module inputs  
• Control module inputs and options  
• Check water system  
• Check expansion tank  
• Check relief valve  
Control module outputs  
• Control module outputs and options  
• 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  
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)  
Troubleshooting  
Control panel parameter access  
• Troubleshooting table - No display  
• Checking temperature sensors  
• Accessing and changing parameters from the display panel  
• Troubleshooting table - Noisy system  
• Troubleshooting table - Fault messages displayed on  
Operator Interface  
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  
• I: Cascade  
• J: Building Management System (BMS)  
• K: Pumps  
• L: Service Notification  
4
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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 move up one level  
in Menu Mode or to exit  
Menu Mode  
• 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  
DISPLAY SCREEN  
MENU/EXIT  
ENTER/RESET  
UP  
DOWN  
PREVIOUS  
NEXT  
• Press to change boiler water  
temperature and/or tank water  
temperature set point during  
normal operation  
• 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  
• Press to change displayed data  
values in Menu Mode  
• Press to navigate through menu  
listing in Menu Mode  
5
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Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual  
1 Service  
Control inputs  
OUTDOOR SENSOR  
(OPTIONAL)  
SYSTEM SUPPLY/  
ENABLE SENSOR  
(OPTIONAL)  
SENSOR  
SYSTEM RETURN/  
CONNECTION  
BOARD  
POOL SENSOR  
LOW  
(OPTIONAL ON BOILER)  
(STD ON POOL HEATER)  
(BOILER AND  
VOLTAGE  
POOL HEATER  
CONNECTION  
ONLY)  
BOARD  
SYSTEM PUMP SPEED  
(OPTIONAL)  
CASCADE  
DHW THERMOSTAT  
(OPTIONAL)  
ROOM THERMOSTAT/  
ZONE CONTROL  
(OPTIONAL)  
SEQUENCER BUILDING  
MANAGEMENT SYSTEM  
(FIELD PROVIDED)  
LOUVER PROVING SWITCH  
(FIELD PROVIDED)  
SMART  
SYSTEM  
CONTROL  
TANK SENSOR  
(OPTIONAL)  
BOARD  
MODBUS  
BOARD  
MODBUS  
(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)  
6
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Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual  
1 Service  
(continued)  
Control outputs  
MODBUS  
LOW  
VOLTAGE  
CONNECTION  
BOARD  
MODBUS  
BOARD  
0-10V  
(OPTIONAL)  
POWER  
CASCADE  
THREE WAY VALVE  
(OPTIONAL ON BOILER)  
(STD ON POOL HEATER)  
LOUVER RELAY  
BUILDING  
MANAGEMENT  
SYSTEM  
RUN TIME CONTACTS  
ALARM CONTACTS  
SMART  
SYSTEM  
CONTROL  
BOARD  
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)  
INDICATES CONNECTIONS MADE TO THE LINE VOLTAGE TERMINAL STRIP LOCATED IN THE CONTROL PANEL AREA  
7
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Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual  
1 Service  
General Operation  
How the appliance operates  
Access modes  
The Copper-fin uses a finned copper tube heat exchanger to User  
transfer heat from the flue products to the water. An electronic  
The user can adjust space heating set point using the UP  
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.  
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  
How the control module operates  
Most parameters are available only to the installer, accessible  
only by entering the installer access code (5309).  
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.  
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.  
Sequence of operation  
To enter a parameter and continue programming:  
Table 1A shows control module normal sequences of operation  
for space heating and DHW operation. The combined operation  
sequence is for a typical application, programmed to provide  
DHW priority.  
Press the MENU/EXIT button 1 time to return to the parameter  
listings; press again to return to the menu listings. Remember  
to press the ENTER/RESET button when finished programming  
in order to save the changes made.  
8
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Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual  
1 Service  
(continued)  
Sequence of operation  
Table 1A_Sequence of Operation - Space Heating and DHW  
OPERATION  
DISPLAY  
HTR: Standby  
OUT: 123.8F(129)  
1. The manual reset high limit (optional) must be closed before  
any action will take place.  
2. Upon a call for heat the control turns on the appropriate  
pumps (system and boiler pumps for space heating; DHW  
pump for DHW call). The flow switch and low water cutoff  
(if equipped) must close.  
HTR: Standby  
OUT: 123.8F(129)  
3. • The gas pressure switch(es) (if equipped) must close.  
• The louver proving input must close.  
HTR: Standby  
OUT: 123.8F(129)  
• If the air pressure switch is open, the prepurge cycle then  
begins by starting the combustion blower. Once started,  
the air pressure switch must close.  
4. After the 15 second prepurge, the blower slows down and  
the hot surface igniter (HSI) is energized. The HSI is heated  
for at least 20 seconds.  
HTR: PREPURGE  
OUT: 123.9F(129)  
HTR: IGNITION  
OUT: 123.9F(129)  
5. Once the HSI is hot, the trial for ignition begins with the  
opening of the gas valve.  
HTR: POSTPURGE, PREPURGE  
OUT: 123.9F(129)  
6. If the SMART SYSTEM control does not sense flame, then  
it will lock out.  
7. If the SMART SYSTEM control senses flame,  
it will fire the burner to maintain the set point. The  
stages will fire as required to hold the actual temperature at  
the set point. If the boiler lights due to a space heating call for  
heat, and the ramp delay function is active (default is  
disabled), the stages will be held to a series of increasing  
limits after the burner has lit.  
HTR: RUN STG: 1  
OUT: 124.8F(129)  
8. If the space heating call for heat is active, and the DHW  
thermostat closes, the control will turn on the DHW pump,  
wait 2 seconds, and then turn off the boiler pump. This will  
divert the hot water away from the heating zone(s) and send  
it to the DHW tank instead. The control will then fire the  
stages to maintain the outlet temperature to the DHW boiler  
set point.  
HTR: DHW STG 123  
OUT: 177.8(180)  
9
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Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual  
1 Service  
Sequence of operation  
Table 1A_(continued from previous page) Sequence of Operation - Space Heating and DHW  
OPERATION  
DISPLAY  
9. If the DHW thermostat remains on for more than  
30  
minutes, and the space heating call for heat is also on, then  
the control will turn on the boiler pump, turn off the DHW  
pump after 2 seconds, and resume firing based on the  
space heating set point. As long as both the space heating  
and DHW calls for heat remain active, the control will switch  
back and forth between the two modes until one of them is  
satisfied.  
HTR: RUN STG 12  
OUT: 123.0F(129)  
10. Once both calls for heat are satisfied, the control will turn  
off the burners. The blower will remain on for the  
30 second postpurge cycle. Any pumps that are running  
will continue to run for their respective pump delay times,  
then turn off.  
HTR: POSTPURGE  
OUT: 127.4F(129)  
HTR: Standby  
OUT: 124.7F(129)  
11. Boiler pump off, system pump continues its delay if  
longer.  
HTR: Standby  
OUT: 122.9F(129)  
12. System pump off.  
10  
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Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual  
1 Service  
(continued)  
Display panel menu access  
Table 1B_Use this procedure to access menus from the display panel  
Note: Not all menu listings shown above are available on water heaters.  
11  
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Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual  
1 Service  
Display panel parameter access  
Table 1C_This is a typical example of accessing a parameter, shown for parameter K2, SH pump delay  
Cascade  
BMS  
12  
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Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual  
1 Service  
(continued)  
Parameter table  
Table 1D_This table lists SMART SYSTEM control module parameters and where to access them  
User Access  
Display Modify Display  
Installer Access  
Sub  
Item  
See  
Page  
Menu  
Description  
Modify  
1
2
3
4
5
6
7
8
1
2
3
4
5
6
User Code  
15  
15  
15  
15  
15  
15  
15  
15  
15  
15  
16  
16  
16  
16  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
No  
Yes  
Yes  
No  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
No  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Time and Date  
Software Version  
Temperature Units  
A
SH Night Setback Offset  
SH Night Setback Times  
DHW Night Setback Offset  
DHW Night Setback Times  
SH User Setpoint  
Minimum SH User Setpoint  
Maximum SH User Setpoint  
SH Offset  
No  
No  
No  
No  
B
C
D
SH Differential  
No  
No  
Manual Reset High Limit  
Yes  
Yes  
7
1
2
3
4
1
2
3
4
5
6
7
1
2
3
4
5
6
1
2
3
4
5
6
7
8
9
Auto Reset High Limit  
Hours Running SH  
16  
16  
16  
16  
16  
16  
16  
16  
16  
17  
17  
17  
17  
17  
17  
17  
17  
17  
18  
18  
18  
18  
18  
19  
19  
19  
19  
Yes  
No  
No  
No  
No  
No  
No  
No  
No  
No  
No  
No  
Yes  
Yes  
No  
No  
No  
No  
No  
No  
No  
No  
Yes  
Yes  
No  
Yes  
Yes  
Yes  
No  
No  
No  
No  
No  
No  
No  
No  
No  
No  
No  
Yes  
Yes  
No  
No  
No  
No  
No  
No  
No  
No  
Yes  
Yes  
No  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Hours Running DHW  
Burner Cycles  
Last 10 Lockouts  
Reset Last 10 Lockouts  
Service Mode Delay  
Display Timeout  
Bypass Valve Time  
Freeze Protection Pump On  
Freeze Protection Burner On  
Freeze Protection Differential  
Tank Setpoint  
DHW Boiler Setpoint  
SH/DHW Switching Time  
DHW/SH Switching Time  
Tank Offset  
E
Tank Differential  
Low Outdoor Temperature  
High Outdoor Temperature  
Setpoint at Low Outdoor Temperature  
Setpoint at High Outdoor Temperature  
Outdoor Shutdown Setpoint  
Outdoor Shutdown Differential  
Shfit Reset Curve  
F
Boost Temperature  
Boost Time  
13  
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Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual  
1 Service  
Parameter table (continued)  
Table 1D_(continued from previous page) This table lists SMART SYSTEM control module parameters and where to  
access them  
User Access  
Installer Access  
Sub  
See  
Menu  
Description  
Anti-cycle Delay  
Item  
Page  
Display Modify Display  
Modify  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
1
2
3
4
1
2
3
4
5
6
19  
19  
19  
19  
20  
20  
20  
20  
20  
20  
No  
No  
No  
No  
No  
No  
No  
No  
No  
No  
No  
No  
No  
No  
No  
No  
No  
No  
No  
No  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Anti-cycle Override Differential  
Min On/Off Time Stages 1, 3  
Delay Between Stages 1, 3  
Controlling Sensor  
G
Enable Input (Active / Inactive)  
BMS Input (Active / Inactive)  
Cascade (Active / Inactive)  
Sequencer  
H
ModBus (Active / Inactive)  
7
1
2
3
4
1
2
3
4
5
6
7
8
9
1
2
3
4
1
ModBus Timeout  
20  
21  
21  
21  
21  
21  
21  
21  
21  
21  
21  
22  
22  
22  
22  
22  
22  
22  
22  
No  
No  
Yes  
No  
No  
No  
No  
No  
No  
No  
No  
No  
No  
No  
No  
No  
No  
No  
No  
No  
No  
Yes  
No  
No  
No  
No  
No  
No  
No  
No  
No  
No  
No  
No  
No  
No  
No  
No  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Cascade Address  
Max. Outlet Set point  
Cascade Offset  
I
Cascade Differential  
BMS Type  
Voltage at Minimum  
Voltage at Maximum  
Power at Low Voltage  
Power at High Voltage  
Setpoint at Low Voltage  
Setpoint at High Voltage  
Voltage to Start CFH  
Voltage Differential CFH  
System Pump Delay  
Boiler Pump Delay  
J
K
L
DHW Pump Delay  
System Pump Mode  
Service Calendar Time (months)  
2
3
4
5
Service Run Time (hours)  
Service Cycles  
22  
22  
22  
22  
No  
No  
No  
No  
No  
No  
No  
No  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Reset Service Reminder  
Personality Plug  
14  
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Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual  
1 Service  
(continued)  
Viewable and changeable control parameters  
Before changing parameters, note the  
settings so that the unit can be returned to  
its original operating parameters.  
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).  
CAUTION  
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.  
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 0°F to 90°F (50°C). The  
default value is 0°F.  
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 been 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.  
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 parameter 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.  
The internal clock does not adjust for  
Daylight Savings Time and therefore, will  
NOTICE  
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.  
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 B1. The temperature range of this  
parameter is 60°F (15°C) to 230°F (110°C). The default value  
is 80°F (27°C).  
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  
B2: SH Minimum set point  
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 0°F. The default value is 0°F.  
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).  
A6: SH Night setback times  
If parameter A5 is set to anything other 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  
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Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual  
1 Service  
B3: SH Maximum set point  
C3: Burner cycles  
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 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 220°F (104°C) (space heating) or 105°F (55°C) (pool heater).  
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.  
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°C) to 54°F (30°C). The default value is 10°F (5°C) (boiler) or  
2°F (1°C) (pool heater).  
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 cleared by the  
installer by accessing parameter D1. Once accessed, press the  
RESET key to clear the counter.  
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).  
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.  
B6: Manual reset high limit  
The SMART SYSTEM control includes an integrated manual  
resethighlimit(MRHL)feature, basedontheoutlettemperature.  
The set point for the MRHL is adjusted using parameter B6.  
The temperature range of this parameter is 32°F (0°C) to 210°F  
(99°C) for water heaters and pool heaters, or 240°F (115°C) for  
boilers. The default value is 210°F (99°C) for boilers and water  
heaters, or 200°F (93°C) for pool heaters.  
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.  
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).  
D4: Bypass valve time  
C: Data logging  
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 temperature 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.  
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 C1.  
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.  
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Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual  
1 Service  
(continued)  
D5: Freeze protection pump on  
E4: DHW/SH switching time (boiler only)  
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).  
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)  
D6: Freeze protection burner on  
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).  
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).  
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).  
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 must 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°C).  
E: 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 E1. The temperature range of this  
parameter is 60°F (15°C) to 190°F (88°C). The default value is  
120°F (49°C).  
E2: DHW boiler set point (boiler only)  
When an 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°C).  
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, then return to the SH demand (if  
active). The default value of this parameter is 30 minutes.  
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Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual  
1 Service  
Figure 1-1_Outdoor Air Reset Curve  
F3: Maximum SH set point  
F: Outdoor air reset (boiler only)  
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). The default value is 180°F  
(82°C).  
Outdoor air reset operation  
When the outdoor air 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  
F4: Minimum SH set point  
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 F1. The temperature range  
of this parameter is -22°F (-30°C) to 86°F (30°C). The default  
value is 25°F (-4°C).  
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  
F2: Maximum air temperature  
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).  
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).  
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Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual  
1 Service  
(continued)  
F6: Outdoor air shutdown differential  
G2: Anti-cycle override 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°C). The default value is 10°F (5°C).  
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).  
F7: Shift reset curve  
The shift reset curve parameter shifts the actual set point above  
or below the calculated set point the number of degrees 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  
0°F (0°C). This feature will be active if this parameter is set to  
anything other than 0°F (0°C).  
G3: Minimum on / off stages 1, 3  
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.  
F8: Boost temperature  
G4: Delay between stages 1, 3  
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 0°F (0°C). This feature will be active if this parameter is set to  
anything other than 0°F (0°C).  
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 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.  
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 delay  
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.  
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Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual  
1 Service  
Figure 1-2_Ramp Delay Interval  
H3: BMS input (active / inactive)  
H: Control modes  
When the building management input is enabled, the control  
modulates the unit or the cascade based on the voltage on the  
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.  
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 done  
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)  
H2: Enable input (active / inactive)  
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.  
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 generate a call  
for heat. Second, the 0-10Vdc voltage from a 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.  
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  
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Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual  
1 Service  
(continued)  
J: Building Management System (BMS)  
I: Cascade  
J1: BMS type  
I1: Cascade address  
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.  
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 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.  
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 0V - (J3 - 0.1V). The default value is 2V.  
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 I2. 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°C).  
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 parameter, 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%.  
I3: Cascade offset (boilers only)  
This parameter determines how much the temperature 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°C). The default value is 9.9°F (5°C).  
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%.  
I4: 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).  
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 J6. 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).  
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21  
Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual  
1 Service  
J7: Set point at high voltage  
K4: System pump mode (boiler only)  
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°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 190°F (88°C) for water  
heaters, 220°F (104°C) for boilers, and 105°F (40°C) (pool  
heaters).  
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.  
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.  
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.  
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.  
J9: Voltage differential CFH  
When the Enable input is set to Inactive, this parameter  
determines the BMS input voltage at which 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 0V - (J8 - 0.1V). The default value is 1V.  
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 cycles. The default is 10,000  
cycles.  
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.  
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.  
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.  
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”.  
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  
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Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual  
2 Maintenance  
Maintenance and annual startup  
Table 2A_Service and Maintenance Schedules  
Service technician  
Owner maintenance  
(see the User’s Information Manual for instructions)  
(see the following pages for instructions)  
• Check appliance area  
General:  
• Address reported problems  
• Check pressure/temperature  
gauge  
• Inspect interior; clean and vacuum if  
necessary;  
Daily  
• Check for leaks (water, gas, flue,  
condensate)  
• Examine venting system  
• Check vent piping  
• Check air piping  
• Check system water pressure/system  
piping/expansion tank  
• Check control settings  
• Check relief valve  
• Check igniters  
Monthly  
• Replace combustion air filter  
Note: Morefrequentreplacementmay  
be necessary in dirty environments.  
Do not use pleated filters.  
• Check wiring and connections  
• Check flue gas passageways  
• Flame inspection (stable, uniform)  
•Inspect and clean the burners  
• Check manifold gas pressures  
• Test low water cutoff (if used)  
Periodically  
• Perform  
start-up  
checkout  
and  
• Reset button (low water cutoff)  
performance verification per the Startup  
Section in the Installation and Operation  
Manual.  
• Check appliance piping (gas and  
water) for leaks  
If combustion or performance  
indicate need:  
Every  
6 months  
• Operate relief valve  
• Clean heat exchanger with a stiff bristle  
brush  
• Remove and clean burners using  
water. Dry before re-assembling.  
• Clean the blower wheel with a brush and  
vacuum. Do not let dirt from cleaning get  
pulled into the blower.  
•Shut appliance down (unless  
boiler used for domestic hot  
water)  
End  
of season  
months  
23  
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Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual  
2 Maintenance  
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, or substantial property damage.  
ƽ 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.  
ƽ WARNING  
Electrical shock hazard – Turn off power to the appliance before any service operation on the appliance except as  
noted otherwise in this instruction manual. Failure to turn off electrical power could result in electrical shock,  
causing severe personal injury or death.  
ƽ WARNING  
Address reported problems  
1. Inspect any problems reported by the owner and correct  
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.  
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  
Check water system  
the appliance.  
1. Verify all system components are correctly installed and  
operational.  
2. Vacuum any sediment from inside the appliance and  
components. Remove any obstructions.  
2. Check the cold fill pressure for the system. Verify it is  
correct (must be a minimum of 12 PSI).  
Check all piping for leaks  
Eliminate all system or appliance leaks.  
Continual fresh makeup water will reduce  
ƽ WARNING  
3. Watch the system pressure as the boiler heats up (during  
testing) to ensure pressure does not rise too high.  
Excessive pressure rise indicates expansion tank sizing or  
performance problem.  
appliance life. Minerals can build up in  
sections, reducing heat transfer, overheating  
heat exchanger, and causing heat exchanger  
failure. Leaking water may also cause severe  
property damage.  
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.  
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.  
Check expansion tank (if provided)  
3. Check gas line using the procedure found in the Gas  
Connections of the Installation and Operation Manual.  
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.  
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.  
Venting system must be sealed gastight  
ƽ WARNING  
to prevent flue gas spillage and carbon  
monoxide emissions, which will result in  
severe personal injury or death.  
24  
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Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual  
2 Maintenance  
(continued)  
Check relief valve  
Inspect/replace hot surface 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.  
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.  
Do not attempt to repair a faulty hot  
ƽ WARNING  
surface igniter or ignition module. Any  
Safety relief valves should be re-inspected  
ƽ WARNING  
modification or repairs may create  
hazardous conditions that result in property  
damage, personal injury, fire, explosion  
and/or toxic gases.  
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  
corrode 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.  
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.  
Following installation, the valve lever must  
ƽ WARNING  
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.  
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.  
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 reinstalled 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.  
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.  
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  
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Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual  
2 Maintenance  
Check all wiring  
Check flue gas passageways  
1. Inspect all wiring, making sure wires are in good condition  
and securely attached.  
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.  
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.  
All gaskets/sealants on disassembled  
NOTICE  
componentsorjacketpanelsmustbereplaced  
with new gaskets/sealants on reassembly.  
Gasket and sealant kits are available from  
your distributor.  
Perform start-up and checks  
1. Start appliance and perform checks and tests specified in  
Start-up Section of the Installation and Operation Manual.  
When  
a
Category IV vent system is  
ƽ CAUTION  
2. Verify cold fill pressure is correct and that operating  
pressure does not go too high.  
disconnected for any reason, the flue must  
be reassembled and resealed according to the  
vent manufacturer’s instructions.  
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 located on either end of the appliance.  
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.  
The area around the burner viewport is hot  
and direct contact could result in burns.  
ƽ WARNING  
Figure 2-1_Flame Pattern Illustration  
NORMAL  
YELLOW TIP  
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.  
FLAME LIFT  
YELLOW FLAME  
Normal Flame: A normal flame at 100% 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.  
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26  
Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual  
2 Maintenance  
(continued)  
Access to the burner will require the following steps:  
Checking combustion air pressure  
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.  
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  
4. Disconnect the manifold(s) from the gas train using the  
union(s) just below each gas valve.  
the 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.  
5. Disconnect the wiring to the hot surface igniter(s) and  
ground.  
6. Disconnect burner pressure line at burner.  
Check for proper installation and draft in the venting system  
prior to any adjustments. Correct as needed.  
7. Remove the screws from the manifold mounting bracket(s)  
and remove the manifold(s).  
Figure 2-2_Adjusting air shutter - 399,999 - 750,000 Btu/  
hr Models  
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.  
LESS AIR  
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,  
MORE AIR  
NOTICE  
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 entering the  
unit.  
AIR SHUTTER  
Figure 2-3_Adjusting air shutter - 990,000 - 2,070,000  
Btu/hr Models  
While burners are removed, check the heat  
NOTICE  
exchanger surface for sooting. If present, the  
heat exchanger must be cleaned. Reference  
the Heat Exchanger Cleaning procedures in  
this manual.  
MORE AIR  
LESS AIR  
AIR SHUTTER  
ADJUSTING BRACKET  
27  
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Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual  
2 Maintenance  
Adjusting combustion air pressure  
Checking manifold gas 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.  
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.  
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.  
4. Connect a hose from the tee used to measure the  
combustion air pressure to the other side of the  
manometer.  
For 399,999 - 750,000 Btu/hr models (reference FIG. 2-2)  
5. Turn the appliance power switch to the “ON” position.  
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.  
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).  
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.  
7. Repeat this process with each gas valve.  
Overfire and underfire hazards!  
ƽ WARNING  
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.  
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.  
If you must adjust the gas valve regulator pressure,  
follow the steps below:  
2. If adjustment is necessary, slightly loosen the nut  
located on the air shutter arm.  
1. Remove the cap covering the manifold 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.  
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.  
2. Make a slight adjustment to the manifold pressure  
adjustment screw. Turning the screw clockwise  
increases manifold pressure and counterclockwise  
decreases manifold pressure.  
All models  
4. Once the adjustment procedure is complete, tighten all  
connections, disconnect the manometer, and replace the  
cap at the tee.  
3. Replace the cap and check the manifold pressure.  
5. Check all connections and test fire the unit.  
6. Replace all panels.  
Note: Allow the unit to re-light if necessary.  
4. Repeat the steps above to match the manifold pressures  
from Table 2B.  
Checking manifold gas pressure  
5. Once the adjustment procedure is complete, turn off  
the appliance, disconnect the manometer, replace and  
tighten all connections, and replace all panels.  
The gas regulator 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.  
6. Turn on the appliance and test fire the unit.  
7. Repeat this process with each gas valve.  
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  
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Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual  
2 Maintenance  
(continued)  
Figure 2-4_Measuring manifold gas pressure  
PRESSURE  
REGULATOR  
ADJUSTMENT  
(UNDER CAP  
SCREW)  
CHAMBER  
PRESSURE  
MANIFOLD  
PRESSURE  
INLET  
TEE  
OUTLET  
GAS  
TO BARBED  
FITTING  
MANOMETER  
VALVE  
CONTROL  
KNOB  
TABLE 2B  
Net Manifold Pressure  
Regulator Pressure Less  
Front Chamber Pressure  
MODEL  
402 - 752  
992 - 2072  
Nat. Gas  
1.8'' w.c.  
1.2'' w.c.  
LP  
4.6’’ w.c.  
4.6’’ w.c.  
29  
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Copper-fin II/IIE 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 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 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.  
HEAT  
EXCHANGER  
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.  
Figure 2-5_Location of the Heat Exchanger Inside Jacket  
Review with owner  
1. Review the User’s Information Manual with the owner.  
10. Check “V” baffles along the front and back edges of the heat  
exchanger (FIG. 2-5). Remove and clean if necessary.  
2. Emphasize the need to perform the maintenance schedule  
specified in the User’s Information Manual (and in this  
manual as well).  
11. Remove soot from the heat exchanger with a stiff bristle  
brush. Use a vacuum to remove loose soot from the  
surfaces and inner chamber.  
3. Remind the owner of the need to call a licensed contractor  
should the appliance or system exhibit any unusual behavior.  
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.  
4. Remind the 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.  
Do not wet the refractory located on the  
inside of the combustion chamber.  
NOTICE  
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.  
Make sure the frame runners seal securely  
where they contact the front and rear  
compartment refractory.  
NOTICE  
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.  
30  
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Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual  
3 Troubleshooting  
Label all wires prior to disconnection when  
servicing controls. Wiring errors can cause  
Check control module fuses  
ƽ WARNING  
ALWAYS check control module fuses before  
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.  
NOTICE  
replacing control module or any major  
components (blower, etc.). If one of these  
fuses is blown, it can prevent the control  
module or other components from operating.  
1. Turn OFF the power to the appliance at the external line  
switch.  
Never jumper (bypass) any device except  
for momentary testing as outlined in the  
Troubleshooting chart. Severe personal  
injury, death, or substantial property damage  
can result.  
ƽ WARNING  
2. Remove front access cover.  
3. Inspect fuses F2, F4, F5, and F6, see FIG. 3-1 below.  
Figure 3-1_Control Module Fuses  
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.  
F6  
5 AMPS  
2. Check for 120 VAC (minimum 102 VAC to maximum  
132 VAC) to appliance.  
F4  
5 AMPS  
F5  
5 AMPS  
3. 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.  
F2  
4. Make sure all external limit controls are installed and  
operating.  
3.15 AMPS  
Check the following:  
1. Wire connectors to control module are securely plugged in  
at the module and originating control.  
4. The appliance is shipped with four (4) spare fuses in a plastic  
bag attached to the control panel.  
2. Gas pressures:  
Refer to the Gas Connections Section of the Installation and  
Operation Manual for detailed information concerning the  
gas supply.  
5. 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.  
Do not jumper fuse or replace with any fuse  
ƽ WARNING  
except as specified. Failure to comply could  
result in severe personal injury, death, or  
substantial property damage.  
6. Install front access cover after fuse inspection.  
7. 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  
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Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual  
3 Troubleshooting  
Table 3A Troubleshooting Chart - No Display  
FAULT  
CAUSE  
CORRECTIVE ACTION  
• Check external line switch, fuse, or breaker.  
• Check position of ON/OFF switch. Turn switch to the  
ON position.  
- No 120 VAC supplied to unit.  
• Check 120 VAC through the ON/OFF switch. No  
voltage through switch, replace switch.  
• Check wiring harness connection between the display  
board and the main control board. Connect the harness  
at both points.  
- Bad wiring connection.  
No Display  
• Replace fuse F6 on the main control board, see  
FIG. 3-1 on page 31 of this manual.  
- Blown fuse.  
- Bad display board.  
• Replace board.  
- Bad main control board.  
• Replace main control board.  
• Review temperature setting.  
- Main control board temperature set point  
satisfied.  
- Remote thermostat satisfied.  
• Review remote thermostat setting.  
No Burner  
Operation  
• Check location of outside air sensor.  
resistance of outdoor air sensor and compare to Table  
3D on page 33 of this manual.  
Check  
- Outside air temperature above Warm  
Weather Shutdown (WWSD) set point for  
main control board.  
• Consult display for specific fault. Refer to fault  
descriptions on pages 35 - 42 of this manual for  
corrective actions.  
- Unit locked out on fault.  
• Check ramp delay parameter settings. Optional PC  
software required.  
- Ramp delay active.  
• Turn ramp delay feature off. See page 18 of this  
manual for instructions on how to turn this feature off.  
Unit Does Not  
Modulate to  
100%  
- Boiler controlled by BMS.  
- Outlet temperature too high.  
- Delta T too high.  
• Check BMS parameter settings.  
software required.  
Optional PC  
32  
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Copper-fin II/IIE 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 all 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  
S1a Inlet/Outlet/System/Tank  
S1b Outlet Only  
(Wire Color - R and W)  
(Wire Color - Bk and G)  
Temperature Resistance Temperature Resistance Temperature Resistance Temperature Resistance  
50  
68  
19,553  
12,690  
8,406  
5,715  
3,958  
2,786  
158  
176  
194  
212  
2,004  
1,464  
1,084  
816  
50  
68  
40,030  
25,030  
16,090  
10,610  
7,166  
158  
176  
194  
212  
3,478  
2,492  
1,816  
1,344  
86  
86  
104  
122  
140  
104  
122  
140  
4,943  
Table 3C Outdoor Air Sensor Resistance vs. Temperature  
Temperature  
Resistance  
Temperature  
Resistance  
-50  
-40  
-30  
-20  
-10  
0
490,813  
336,606  
234,196  
165,180  
118,018  
85,362  
20  
30  
40  
50  
60  
70  
80  
46,218  
34,558  
26,099  
19,900  
15,311  
11,883  
9,299  
10  
62,465  
33  
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Copper-fin II/IIE 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.  
- Dirty/damaged burner.  
• 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.  
• Refer to pages 26 and 27 in this manual for the burner  
removal and inspection procedure. Clean or replace the  
burner as necessary.  
Noisy  
Operation  
- 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.  
• Verify system pressure is a minimum of 12 PSI.  
- Low system water pressure.  
- Faulty pump relay.  
• Replace relay.  
• Replace pump.  
No Pump  
Operation -  
Boiler Pump  
System Pump  
or  
- Faulty pump.  
- Internal fault on control board.  
• Check fuse F5.  
• Replace main control board.  
DHW Pump  
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  
Opening  
- Improperly sized expansion tank.  
• Install properly sized expansion tank.  
• Check set point of temperature control.  
- Outlet water temperature in excess of 210°.  
• Check temperature rise across heat exchanger. Refer to  
the temperature rise chart in the Water  
Connections Section of the Installation and Operation  
Manual.  
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34  
Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual  
3 Troubleshooting  
(continued)  
Table 3E 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  
cause of failure. Refer to the Gas Connections  
Section of the Installation and Operation Manual for  
detailed information concerning the gas supply.  
Gas Pressure SW  
(Will require a manual  
reset once the condition  
has been corrected.)  
- Models 992 - 2072 (natural gas) - Automatic  
Reset Low Gas is open.  
• 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.  
Flow Switch/  
LWCO  
• Check for closed valves or obstructions in the  
water piping.  
(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.)  
• Verify system is full of water and all air has been  
purged from the system.  
The flame detector circuit is seeing a flame • Check supply voltage for proper polarity.  
signal while the gas valve is de-energized.  
Flame Sequence  
(Will require a manual  
reset once the condition  
has been corrected. Press  
the RESET button on the  
SMART SYSTEM display  
to reset.)  
• Check that the gas valve is closed.  
• Check external wiring for voltage feedback.  
• Check the internal wiring for bad connections.  
• 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  
heat has ended.  
a set time period.  
Anti-cycling  
• The control board will release the call for heat if the  
outlet temperature drops too quickly.  
35  
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Copper-fin II/IIE 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.  
necessary.  
Replace if  
• 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 that the tube from the gas valve to the combustion  
air chamber is connected and is not damaged.  
No Flame Ign  
(Will require a manual  
reset. Press the RESET  
button on the SMART  
SYSTEM display to reset.)  
• Verify that the vent/air intake pipes are correctly  
installed and that there are no obstructions.  
• Inspect the burners. Reference pages 26 and 27  
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  
HSI Current Low  
(Will require a manual  
reset once the condition  
has been corrected. Press  
the RESET button on the  
SMART SYSTEM display  
to reset.)  
meet the minimum requirement of 2.6 amps.  
the trial for ignition stage. If less than 2.6 amps  
replace the hot surface igniter.  
• If more than 2.6 amps replace the control module.  
The main control board has detected an • Replace the main control board.  
internal fault.  
Flame CKT  
Error  
36  
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Copper-fin II/IIE 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  
The unit was running and lost the flame signal. • Inspect igniter and associated wiring for damage and  
connection. Reference page 25 of this manual for  
removal and cleaning procedure.  
necessary.  
Replace if  
• 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.  
No Flame  
Running  
(Will require a manual  
reset once the condition  
has been corrected. Press  
the RESET button on the  
SMART SYSTEM display  
to reset.)  
• 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.  
The outlet water temperature has exceeded the • Verify that the system is full of water and that all air  
setting of the automatic reset high limit.  
has been properly purged from the system.  
• 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 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 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.  
Auto Reset  
High Limit  
• 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.  
37  
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Copper-fin II/IIE 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 outlet water temperature has exceeded • Verify setting of adjustable high limit.  
the setting of the 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.  
Manual Reset  
High Limit  
• 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.  
(Will require a manual  
reset once condition has  
been corrected. Press  
the RESET button on  
the SMART SYSTEM  
display to reset.)  
• 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.  
The inlet water temperature did not exceed  
130° within 15 minutes of ignition.  
• 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.  
Inlet Low  
• 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.  
Sensor Open  
(Will require a manual  
reset once the condition  
has been corrected. Press  
the RESET button on the  
SMART SYSTEM display  
to reset.)  
Either the inlet water, outlet water, system  
supply, systemreturn, oroutdoortemperature  
sensor has been disconnected.  
• Measure the resistance of the sensors and compare  
the resistance to the tables on page 33 of this  
manual.  
• Replace the sensor if necessary.  
Either the inlet water, outlet water, system • Check the sensors and their associated wiring.  
Sensor Shorted  
(Will require a manual  
reset once the condition  
has been corrected. Press  
the RESET button on the  
SMART SYSTEM display  
to reset.)  
supply, systemreturn, oroutdoortemperature  
sensor has been shorted.  
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.  
38  
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Copper-fin II/IIE 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  
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.)  
• Check function of remote devices.  
An optional remote proving switch is not  
making.  
• Check for loose or misplaced jumper if  
proving switch is not installed.  
• Check the tank temperature.  
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.  
®
• Repair or replace the sensor wiring if damaged.  
• Replace the sensor if necessary.  
Tank Open  
• Check air filter. Clean or replace as necessary.  
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.)  
• Vent/air intake lengths exceed the maximum allowed  
lengths.  
The air pressure switch did not make within  
1 minute after the combustion air blower has  
been energized.  
• Check for blockage or obstruction in vent/air inlet pipe  
or at terminations.  
• Verify combustion air blower is operating. Replace if  
necessary.  
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.)  
• Check for jumper on air pressure switch.  
The SMART SYSTEM control sensed that  
the air pressure switch was closed before the  
combustion air blower was energized.  
• 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.  
Control module ID plug does not match • Verify that the number on the ID plug matches the  
Wrong ID Plug  
parameter L5.  
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). If  
so, press the ENTER button on the SMART  
SYSTEM display. If not, replace the control module.  
39  
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Copper-fin II/IIE 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  
exchanger has exceeded the set parameters  
for the appliance.  
• 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 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  
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.)  
• If 120 VAC is present on a call for heat and the  
pump is not operating, replace the pump.  
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 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 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  
the unit.  
Rem Ctrl Flt  
• Replace the control.  
40  
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Copper-fin II/IIE 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,  
the main control board must be reset.  
• Press the ENTER/RESET button on the Smart  
System display panel.  
Parameters  
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 • 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  
• Check 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  
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Copper-fin II/IIE 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  
• Cycle main power.  
The main control board has detected an  
internal fault.  
Watch Dog Error  
• Replace the main control board.  
• Cycle main power.  
The main control board has detected an  
internal fault.  
Write EEProm  
• Replace the main control board.  
• Cycle main power.  
The main control board has detected an  
internal fault.  
Program EEProm  
• Replace the main control board.  
• Cycle main power.  
CRC Parameters  
No Error Stored  
The main control board has detected an  
internal fault.  
• Replace the main control board.  
• Restore default parameters using the PC program.  
• Press RESET.  
The main control board has detected an  
internal fault.  
• Cycle main power.  
• Replace the main control board.  
42  
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NOTES  
43  
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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  
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