Page 2 - Hazard definitions; DANGER; Contents
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 s...
Page 3 - Service Manual; Please read before proceeding; Installer –; When servicing appliance –; Handling ceramic fiber materials; REMOVAL OF COMBUSTION CHAMBER LINING; WARNING; NIOSH stated First Aid.
Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual Please read before proceeding Installer – Read all instructions, including this manual and the Installation and Operation Manual, before installing. Perform steps in the order given. User – This manual is for use only by a qualified heat...
Page 4 - What is in this manual?; Service; • Display panel readout, buttons and their functions; Maintenance
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• A...
Page 5 - DISPLAY SCREEN; The Copper-fin display
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)• Press ...
Page 6 - Control inputs
1 Service 6 SMART SYSTEMCONTROL BOARD LOW VOLTAGE CONNECTION BOARD DHW THERMOSTAT(OPTIONAL) ROOM THERMOSTAT/ZONE CONTROL(OPTIONAL) SYSTEM SUPPLY/ENABLE SENSOR(OPTIONAL) SYSTEM RETURN/POOL SENSOR(OPTIONAL ON BOILER)(STD ON POOL HEATER) SEQUENCER BUILDINGMANAGEMENT SYSTEM(FIELD PROVIDED) OUTDOOR SENSO...
Page 7 - Control outputs
7 SMART SYSTEM CONTROL BOARD LOW VOLTAGE CONNECTION BOARD THREE WAY VALVE (OPTIONAL ON BOILER) (STD ON POOL HEATER) LOUVER RELAY BUILDING MANAGEMENT SYSTEM RUN TIME CONTACTS ALARM CONTACTS ALARM (OPTIONAL) HEATER PUMP (BOILER ONLY) SYSTEM PUMP RELAY DHW PUMP RELAY (BOILER) DHW PUMP (WATER HEATER) HO...
Page 8 - General Operation; How the appliance operates; Access modes; Saving parameters; To save parameters and exit programming:
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 - Sequence of operation; Table 1A_Sequence of Operation - Space Heating and DHW; OPERATION
9 Sequence of operation Table 1A_Sequence of Operation - Space Heating and DHW 1 Service (continued) OPERATION DISPLAY 1. The manual reset high limit (optional) must be closed before any action will take place. HTR: Standby OUT: 123.8F(129) 2. Upon a call for heat the control turns on the appropriat...
Page 10 - If the DHW thermostat remains on for more than 30
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 - Display panel menu access; Table 1B_Use this procedure to access menus from the display panel; Not all menu listings shown above are available on water heaters.
11 Display panel menu access Table 1B_Use this procedure to access menus from the display panel 1 Service (continued) Note: Not all menu listings shown above are available on water heaters. Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual
Page 12 - Display panel parameter access
1 Service 12 Display panel parameter access Cascade BMS Table 1C_This is a typical example of accessing a parameter, shown for parameter K2, SH pump delay Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual
Page 13 - Parameter table
13 Parameter table Table 1D_This table lists SMART SYSTEM control module parameters and where to access them 1 Service (continued) Menu Sub Item Description See Page User Access Installer Access Display Modify Display Modify A 1 User Code 15 Yes Yes Yes Yes 2 Time and Date 15 Yes Yes Yes Yes 3 Softw...
Page 15 - Viewable and changeable control parameters; must be accessed. The default; NOTICE; . The temperature range for this
15 Viewable and changeable control parameters A: General A1: User code The User Code allows the user to access and change a limited number of control parameters. The access code can be changed by the user or the installer to a code of their choosing. To change the code, parameter A1 must be accessed...
Page 17 - . The range of this parameter is 0 to 240 minutes. Setting; E6: Tank differential; . The temperature range of this parameter; D5: Freeze protection pump on; Freeze Protection Pump On; D7: Freeze protection differential; . The temperature range of this
1 Service (continued) 17 Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual E4: DHW/SH switching time (boiler only) The time that the SMART SYSTEM control services a DHW demand before returning to the SH demand is set by parameter E4 . The range of this parameter is 0 to 240 minutes. Set...
Page 19 - F6: Outdoor air shutdown differential
1 Service (continued) 19 F6: Outdoor air shutdown differential The outdoor air shutdown differential parameter is the number of degrees below parameter F5 the outdoor air temperature must go before the unit will respond to a SH demand. This parameter can be changed by the user or the installer by ac...
Page 20 - Section J
H: Control modes H1: SH controlling sensor (boiler only) The SH controlling sensor parameter selects the sensor the control will use to regulate the boiler firing rate. This parameter is adjustable by the installer by accessing parameter H1 . The sensor selections are as follows: The outlet sensor r...
Page 21 - J2: Voltage at minimum
1 Service (continued) 21 I: Cascade I1: Cascade address The boiler designated as the Leader needs to be programmed with address 0. All the Member boilers require addresses from 1 to 7, and the addresses must be different for each Member. The addresses can be in any order, regardless of the order in ...
Page 22 - L: Service Notification; L4: Reset service reminder
22 K4: System pump mode (boiler only) The system pump can be configured to operate in one of two modes. “CFH” runs the system pump whenever there is a SH demand. “WWSD” runs the system pump continuously, except when the boiler is blocked due to outdoor shutdown. To adjust the System Pump Mode, acces...
Page 23 - (see the following pages for instructions); Owner maintenance; (see the User’s Information Manual for instructions); Table 2A_Service and Maintenance Schedules
2 Maintenance 23 Maintenance and annual startup Service technician (see the following pages for instructions) General: • Address reported problems • Inspect interior; clean and vacuum if necessary; • Check for leaks (water, gas, flue, condensate) • Examine venting system • Check system water pressur...
Page 24 - Water Connections Section
24 Follow the service and maintenance procedures given throughout this manual and in component literature shipped with the appliance. Failure to perform the service and maintenance could result in damage to the appliance or system. Failure to follow the directions in this manual and component litera...
Page 25 - Check relief valve; Water Connections; Inspect/replace hot surface igniter; Inspect/replace hot surface igniters
2 Maintenance (continued) 25 Check relief valve 1. Inspect the relief valve and lift the lever to verify flow. Before operating any relief valve, ensure that it is piped with its discharge in a safe area to avoid severe scald potential. Read the Water Connections Section of the Installation and Oper...
Page 27 - Access to the burner will require the following steps:; Heat Exchanger Cleaning; Checking combustion air pressure; Checking / Adjusting Combustion Air Pressure
27 2 Maintenance (continued) Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual Access to the burner will require the following steps: 1. Turn off main electrical power to the appliance. 2. Turn off main manual gas shutoff to the appliance. 3. Remove the lower outer front access door. 4....
Page 28 - Adjusting combustion air pressure; All models; Checking Combustion Air; Checking manifold gas pressure
2 Maintenance 28 Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual Adjusting combustion air pressure The following is a recommended method for setting the combustion air pressure. The following pressure settings are for installations up to 4000 feet altitude. Contact the factory for hig...
Page 29 - INLET; TABLE 2B; MODEL
2 Maintenance (continued) 29 Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual PRESSUREREGULATORADJUSTMENT(UNDER CAPSCREW ) INLET OUTLET GASVALVECONTROLKNOB MANOMETER MANIFOLDPRESSURE CHAMBERPRESSURE TEE TO BARBEDFITTING Figure 2-4_Measuring manifold gas pressure TABLE 2B Net Manifold P...
Page 30 - Inspect and clean the heat exchanger; Figure 2-5_Location of the Heat Exchanger Inside Jacket; Review with owner
2 Maintenance Copper-fin II/IIE Boiler, Water Heater and Pool Service Manual Inspect and clean the heat exchanger 1. Turn off the main electrical power to the appliance. 2. Turn off the main manual gas shutoff to the appliance. 3. Remove the lower outer fron access door. 4. Disconnect the manifold(s...
Page 31 - Troubleshooting; Before troubleshooting:; Section
3 Troubleshooting 31 Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Always disconnect power to the appliance before servicing. Failure to comply could result in severe personal injury, death, or substantial property damage. N...
Page 32 - FAULT; No Display; No Burner; Unit Does Not; Table 3A Troubleshooting Chart - No Display
3 Troubleshooting 32 FAULT CAUSE CORRECTIVE ACTION No Display - No 120 VAC supplied to unit. • Check external line switch, fuse, or breaker. • Check position of ON/OFF switch. Turn switch to the ON position. • Check 120 VAC through the ON/OFF switch. No voltage through switch, replace switch. - Bad ...
Page 33 - Temperature; Checking temperature sensors; Table 3C Outdoor Air Sensor Resistance vs. Temperature; S1b Outlet Only; Resistance
3 Troubleshooting (continued) 33 Temperature Resistance Temperature Resistance -50 490,813 20 46,218 -40 336,606 30 34,558 -30 234,196 40 26,099 -20 165,180 50 19,900 -10 118,018 60 15,311 0 85,362 70 11,883 10 62,465 80 9,299 Checking temperature sensors The appliance temperature sensors (inlet wat...
Page 34 - Table 3D Troubleshooting Chart - Noisy System
3 Troubleshooting 34 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 35 - Gas Pressure SW; LWCO
3 Troubleshooting (continued) 35 FAULT DESCRIPTION CORRECTIVE ACTION Gas Pressure SW (Will require a manual reset once the condition has been corrected.) - Either the optional manual reset low gas pressure switch or the optional manual reset high gas pressure switch tripped. - Models 992 - 2072 (nat...
Page 36 - No Flame Ign; HSI Current Low
3 Troubleshooting 36 FAULT DESCRIPTION CORRECTIVE ACTION No Flame Ign (Will require a manual reset. Press the RESET button on the SMART SYSTEM display to reset.) The unit has failed to prove burner flame upon ignition. • Inspect igniter and associated wiring for damage and connection. Reference page...
Page 37 - No Flame; Auto Reset
3 Troubleshooting (continued) 37 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 38 - Manual Reset; Inlet Low; Sensor Open
38 FAULT DESCRIPTION CORRECTIVE ACTION Manual Reset High Limit (Will require a manual reset once condition has been corrected. Press the RESET button on the SMART SYSTEM display to reset.) The outlet water temperature has exceeded the setting of the adjustable high limit. • Verify setting of adjusta...
Page 39 - Louver Proving
3 Troubleshooting (continued) 39 FAULT DESCRIPTION CORRECTIVE ACTION Louver Proving (Lockout will reset automatically after 5 minutes or may be reset immediately once condition has been corrected. Press the RESET button on the SMART SYSTEM display to reset.) An optional remote proving switch is not ...
Page 40 - Rem Ctrl Flt
3 Troubleshooting 40 FAULT DESCRIPTION CORRECTIVE ACTION Temp O/Shoot (Lockout will reset automatically after 5 minutes or may be reset immediately once condition has been corrected. Press the RESET button on the SMART SYSTEM display to reset.) The temperature rise across the heat exchanger has exce...
Page 41 - Parameters; Service Blk; Low Voltage
3 Troubleshooting (continued) 41 FAULT DESCRIPTION CORRECTIVE ACTION Parameters Progr (Will require a manual reset once the condition has been corrected. Press the RESET button on the SMART SYSTEM display to reset.) After downloading parameters from a laptop, the main control board must be reset. • ...
Page 42 - Watch Dog Error
3 Troubleshooting 42 FAULT DESCRIPTION CORRECTIVE ACTION Watch Dog Error The main control board has detected an internal fault. • Cycle main power. • Replace the main control board. Write EEProm The main control board has detected an internal fault. • Cycle main power. • Replace the main control boa...
Page 43 - NOTES
