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Lochinvar 2072 Service Manual

Other manuals for 2072: Communication Instruction Manual
Manual is about: Copper-fin II/IIE Boiler and Water Heater

Summary of 2072

  • Page 1

    Copper-fin ii/iie boiler and water heater service manual models: 402 - 2072 this manual must only be used by a qualified heating installer / service technician. Read all instructions, including this manual and the installation and operation manual, before installing. Perform steps in the order given...

  • Page 2: Hazard Definitions

    2 hazard definitions the following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product. Danger warning caution caution notice danger indicates an imminently hazardous situati...

  • Page 3

    Copper-fin ii/iie boiler and water heater service manual please read before proceeding installer – read all instructions, including this manual and the installation and operation manual, before installing. Perform steps in the order given. User – this manual is for use only by a qualified heating in...

  • Page 4: What Is In This Manual?

    4 what is in this manual? Service the copper-fin display • display panel readout, buttons and their functions control module inputs • control module inputs and options control module outputs • control module outputs and options general • how the appliance operates • how the control module operates •...

  • Page 5: Service

    1 service 5 menu/exit display screen enter/reset t x e n s u o i v e r p n w o d p u • press to turn heater off or back on • press to select a menu item • press after parameter programming to store parameter data • press to exit service mode • hold 5 seconds to enter code input mode (menu mode) • pr...

  • Page 6: Service

    1 service 6 smart system control board low voltage connection board dhw thermostat (optional) room thermostat/ zone control (optional) system supply/ enable sensor (optional) system return sensor (optional on boiler) sequencer building management system (field provided) outdoor sensor (optional) lou...

  • Page 7: Service

    7 smart system control board low voltage connection board three way valve (optional on boiler) louver relay building management system run time contacts alarm contacts alarm (optional) unit pump system pump relay dhw pump relay (boiler) hot surface igniter blower gas valves display panel pc interfac...

  • Page 8: Service

    1 service 8 general operation how the appliance operates the copper-fin uses a finned copper tube heat exchanger to transfer heat from the flue products to the water. An electronic control module monitors various inputs to initiate a call for heat. The blower provides both primary and secondary air ...

  • Page 9: Service

    9 sequence of operation table 1a_sequence of operation - space heating and dhw 1 service (continued) operation display 1. The manual reset high limit must be closed before any action will take place. Htr: standby out: 123.8f(129) 2. Upon a call for heat the control turns on the appropriate pumps (sy...

  • Page 10: Service

    1 service 10 sequence of operation table 1a_(continued from previous page) sequence of operation - space heating and dhw operation display 9. If the dhw thermostat remains on for more than 30 minutes, and the space heating call for heat is also on, then the control will turn on the boiler pump, turn...

  • Page 11: Service

    11 display panel menu access table 1b_use this procedure to access menus from the display panel 1 service (continued) note: not all menu listings shown above are available on water heaters. Copper-fin ii/iie boiler and water heater service manual.

  • Page 12: Service

    1 service 12 display panel parameter access cascade bms table 1c_this is a typical example of accessing a parameter, shown for parameter k2, sh pump delay copper-fin ii/iie boiler and water heater service manual.

  • Page 13: Service

    13 parameter table a - boiler operation table 1d_this table lists smart system control module parameters and where to access them for boiler operation only 1 service (continued) menu sub item description see page user access installer access display modify display modify a 1 user code 17 yes yes yes...

  • Page 14: Service

    1 service 14 parameter table a - boiler operation (continued) table 1d_(continued from previous page)this table lists smart system control module parameters and where to access them for boiler operation only menu sub item description see page user access installer access display modify display modif...

  • Page 15: Service

    Parameter table b - water heater operation table 1e_this table lists smart system control module parameters and where to access them for water heater operation only 1 service (continued) menu sub item description see page user access installer access display modify display modify a 1 user code 17 ye...

  • Page 16: Service

    Parameter table b - water heater operation (continued) table 1e_(continued from previous page)this table lists smart system control module parameters and where to access them for water heater operation only menu sub item description see page user access installer access display modify display modify...

  • Page 17: Service

    17 viewable and changeable control parameters general 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. The default code is 0704. The code can be changed one di...

  • Page 18: Service

    1 service 18 sh maximum setpoint (boiler only) the sh maximum setpoint sets the maximum water temperature setpoint that can be used for space heating. The user or installer will not be able to program the control with a higher sh setpoint. The temperature range of this parameter is 32°f (0°c) to 230...

  • Page 19: Service

    1 service (continued) 19 copper-fin ii/iie boiler and water heater service manual dhw/sh switching time (boiler only) the time that the smart system control services a dhw demand before returning to the sh demand is set by this parameter. The range of this parameter is 0 to 240 minutes. Setting this...

  • Page 20: Service

    1 service 20 maximum sh setpoint when the outdoor temperature drops to its minimum setting (f1) the water temperature setpoint will be at this value, if the sh setpoint is set higher (fig. 1-1). The temperature range of this parameter is 32°f (0°c) to 248°f (120°c). The default value is 180°f (82°c)...

  • Page 21: Service

    1 service (continued) 21 outdoor air shutdown differential the outdoor air shutdown differential parameter is the number of degrees below parameter f5 the outdoor air temperature must go before the unit will respond to a sh demand. The temperature range of this parameter is 0°f (0°c) to 90°f (50°c)....

  • Page 22: Service

    Control modes sh controlling sensor (boiler only) the sh controlling sensor parameter selects the sensor the control will use to regulate the boiler firing rate. The sensor selections are as follows: the outlet sensor regulates the firing rate based on the outlet water temperature of the unit and th...

  • Page 23: Service

    1 service (continued) 23 cascade boiler address the boiler designated as the leader needs to be programmed with address 0. All the member boilers require addresses from 1 to 7, and the addresses must be different for each member. The addresses can be in any order, regardless of the order in which th...

  • Page 24: Service

    24 service notification service interval 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. The time range for this parameter ...

  • Page 25: Maintenance

    2 maintenance 25 maintenance and annual startup service technician (see the following pages for instructions) general: • address reported problems • inspect interior; clean and vacuum if necessary; • check for leaks (water, gas, flue, condensate) • examine venting system • check system water pressur...

  • Page 26: Maintenance

    26 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 litera...

  • Page 27: Maintenance

    2 maintenance (continued) 27 check relief valve 1. Inspect the relief valve and lift the lever to verify flow. Before operating any relief valve, ensure that it is piped with its discharge in a safe area to avoid severe scald potential. Read the water connections section of the installation and oper...

  • Page 28: Maintenance

    28 2 maintenance copper-fin ii/iie boiler and water heater service manual check all wiring 1. Inspect all wiring, making sure wires are in good condition and securely attached. Check control settings 1. Set the smart system control module display to parameter mode and check all settings. See section...

  • Page 29: Maintenance

    29 2 maintenance (continued) copper-fin ii/iie boiler and water heater service manual access to the burners will require the following steps: 1. Turn off main electrical power to the appliance. 2. Turn off main manual gas shutoff to the appliance. 3. Remove the upper and lower outer front access doo...

  • Page 30: Maintenance

    2 maintenance 30 copper-fin ii/iie boiler and water heater service manual adjusting combustion air pressure the following is a recommended method for setting the combustion air pressure. The following pressure settings are for installations up to 4000 feet altitude. Contact the factory for high alti...

  • Page 31: Maintenance

    2 maintenance (continued) 31 copper-fin ii/iie boiler and water heater service manual pressure regulator adjustment (under cap screw) inlet outlet gas valve control knob manometer manifold pressure chamber pressure tee to barbed fitting figure 2-4_measuring manifold gas pressure table 2b net manifol...

  • Page 32: Maintenance

    2 maintenance copper-fin ii/iie boiler and water heater service manual inspect and clean the heat exchanger 1. Turn off the main electrical power to the appliance. 2. Turn off the main manual gas shutoff to the appliance. 3. Remove the lower outer fron access door. 4. Disconnect the manifold(s) from...

  • Page 33: Troubleshooting

    3 troubleshooting 33 label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Always disconnect power to the appliance before servicing. Failure to comply could result in severe personal injury, death, or substantial property damage. N...

  • Page 34: Troubleshooting

    3 troubleshooting 34 fault cause corrective action no display - no 120 vac supplied to unit. • check external line switch, fuse, or breaker. • check position of on/off switch. Turn switch to the on position. • check 120 vac through the on/off switch. No voltage through switch, replace switch. - bad ...

  • Page 35: Troubleshooting

    3 troubleshooting (continued) 35 temperature resistance temperature resistance -50 490,813 20 46,218 -40 336,606 30 34,558 -30 234,196 40 26,099 -20 165,180 50 19,900 -10 118,018 60 15,311 0 85,362 70 11,883 10 62,465 80 9,299 checking temperature sensors the appliance temperature sensors (inlet wat...

  • Page 36: Troubleshooting

    3 troubleshooting 36 fault cause corrective action noisy operation - gas supply problem. • refer to the gas connections section of the installation and operation manual for detailed information concerning the gas supply. - gas/air mixture problem. • refer to the checking manifold gas pressure and co...

  • Page 37: Troubleshooting

    3 troubleshooting (continued) 37 fault description corrective action gas pressure sw (will require a manual reset once the condition has been corrected.) - either the optional manual reset low gas pressure switch or the optional manual reset high gas pressure switch tripped. - models 992 - 2072 (nat...

  • Page 38: Troubleshooting

    3 troubleshooting 38 fault description corrective action no flame ign (will require a manual reset. Press the reset button on the smart system display to reset.) the unit has failed to prove burner flame upon ignition. • inspect igniter and associated wiring for damage and connection. Reference page...

  • Page 39: Troubleshooting

    3 troubleshooting (continued) 39 fault description corrective action 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.) the unit was running and lost the flame signal. • inspect igniter and associated wir...

  • Page 40: Troubleshooting

    40 fault description corrective action manual reset high limit (will require a manual reset once condition has been corrected. Press the reset button on the smart system display to reset.) the outlet water temperature has exceeded the setting of the adjustable high limit. • verify setting of adjusta...

  • Page 41: Troubleshooting

    3 troubleshooting (continued) 41 fault description corrective action louver proving (lockout will reset automatically after 5 minutes or may be reset immediately once condition has been corrected. Press the reset button on the smart system display to reset.) an optional remote proving switch is not ...

  • Page 42: Troubleshooting

    3 troubleshooting 42 fault description corrective action temp o/shoot (lockout will reset automatically after 5 minutes or may be reset immediately once condition has been corrected. Press the reset button on the smart system display to reset.) the temperature rise across the heat exchanger has exce...

  • Page 43: Troubleshooting

    3 troubleshooting (continued) 43 fault description corrective action service blk while the unit is in service mode, the outlet temperature has exceeded 185°f (85°c). • establish a heating load to remove heat from the system. • verify that the system is full of water and that all air has been properl...

  • Page 44

    Revision notes: revision a (eco #c11226) initial release to reflect the new manual name and removal of the pool heater information. Revision b (eco c11706) reflects the update of information with the “sh controlling sensor (boiler only)” section on page 22. Revision c (eco c13992) reflects edits mad...