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CFX-CHX-SER Rev A
Copper-fin II/IIE
Boiler and Water
Heater
Service Manual
Models: 402 - 2072
This manual must only be used
WARNING
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. Failure to comply
could result in severe personal
injury, death, or substantial
property damage.
Save this manual for future reference.
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Contents 2. MAINTENANCE CONTENTS ........................................................................ 2 Maintenance and Annual Startup ................................ 25-32 Hazard Definitions .............................................................. 2 3. TROUBLESHOOTING PLEASE READ BEFORE PROCEEDING ........................ 3 Before Troubleshooting .................................................... 33 Handling Ceramic Fiber Materials ...................................... 3 Check C
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Copper-fin II/IIE Boiler and Water Heater Service Manual Please read before proceeding Installer – Read all instructions, including When servicing appliance – WARNING this manual and the Installation and � To avoid electric shock, disconnect electrical supply Operation Manual, before installing. before performing maintenance. Perform steps in the order given. � To avoid severe burns, allow appliance to cool before performing maintenance. User – This manual is for use only by a qualif
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Copper-fin II/IIE Boiler and Water Heater Service Manual What is in this manual? Maintenance Service � Service and maintenance schedules The Copper-fin display � Address reported problems � Display panel readout, buttons and their functions � Inspect appliance area and appliance interior Control module inputs � Check all piping for leaks � Control module inputs and options � Flue vent system and air piping � Combustion air filter Control module outputs � Check water system � Control module outp
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Copper-fin II/IIE Boiler and Water Heater Service Manual 1 Service The Copper-fin display � Hold 5 seconds to enter code Input Mode (Menu Mode) � 2-Line / 16 character LCD display • Press to turn heater off or back on � Press to move up one level � Backlit LCD � Press to select a menu item in Menu Mode or to exit � Press after parameter programming to store parameter data Menu Mode � Press to exit Service Mode MENU/EXIT DISPLAY SCREEN ENTER/RESET UP DOWN PREVIOUS NEXT � Press to ch
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Copper-fin II/IIE Boiler and Water Heater Service Manual 1 Service Control inputs OUTDOOR SENSOR (OPTIONAL) SYSTEM SUPPLY/ ENABLE SENSOR (OPTIONAL) SENSOR SYSTEM RETURN SENSOR CONNECTION BOARD (OPTIONAL ON BOILER) LOW (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 SMART (FIELD PROVIDED) SYSTEM CONTROL TAN
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Copper-fin II/IIE Boiler and Water Heater Service Manual 1 Service (continued) Control outputs MODBUS LOW VOLTAGE MODBUS CONNECTION BOARD 0-10V BOARD (OPTIONAL) FIRING RATE CASCADE THREE WAY VALVE (OPTIONAL ON BOILER) LOUVER RELAY BUILDING MANAGEMENT SYSTEM RUN TIME CONTACTS ALARM CONTACTS SMART SYSTEM ALARM CONTROL (OPTIONAL) BOARD UNIT PUMP SYSTEM PUMP RELAY DHW PUMP RELAY (BOILER) HOT SURFACE IGNITER BLOWER GAS VALVES DISPLAY PANEL PC INTERFACE (OPTIONAL) INDICATES CONNECTIONS MADE
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Copper-fin II/IIE Boiler and Water Heater 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 and/or tank setpoints using control module monitors various inputs to initiate a call for the UP and DOWN buttons at any time during normal heat. The blower provides both primary and secondary air to op
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Copper-fin II/IIE Boiler and Water Heater Service Manual 1 Service (continued) Sequence of operation Table 1A_Sequence of Operation - Space Heating and DHW OPERATION DISPLAY HTR: Standby 1. The manual reset high limit must be closed before any action will take place. OUT: 123.8F(129) 2. Upon a call for heat the control turns on the appropriate HTR: Standby pumps (system and boiler pumps for space heating; DHW OUT: 123.8F(129) pump for DHW call). The flow switch and low water cutoff (if eq
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Copper-fin II/IIE Boiler and Water Heater 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 HTR: RUN STG 12 heating setpoint. As long as both the space heating
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Copper-fin II/IIE Boiler and Water Heater 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 and Water Heater 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 and Water Heater Service Manual 1 Service (continued) Parameter table A - Boiler Operation Table 1D_This table lists SMART SYSTEM control module parameters and where to access them for boiler operation ONLY User Access Installer Access Sub See Menu Description Item Page Display Modify Display Modify 1 User Code 17 Yes Yes Yes Yes 2 Date and Time 17 Yes Yes Yes Yes 3 Software Version (Software Ver) 17 Yes No Yes Yes 4 Temperature Units (Temp Units) 17 Yes Yes Yes Yes
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Copper-fin II/IIE Boiler and Water Heater Service Manual 1 Service 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 User Access Installer Access Sub See Menu Description Item Page Display Modify Display Modify 1 Anti-cycle Time (Anti Cycl Tm) 21 No No Yes Yes 2 Anti-cycle Override Differential (Override Diff) 21 No No Yes Yes G 3 Minimum On/Off De
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Copper-fin II/IIE Boiler and Water Heater Service Manual 1 Service (continued) 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 User Access Installer Access Sub See Menu Description Item Page Display Modify Display Modify 1 User Code 17 Yes Yes Yes Yes 2 Date and Time 17 Yes Yes Yes Yes 3 Software Version (Software Ver) 17 Yes No Yes Yes A 4 Temperature Units (Temp Units) 17 Ye
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Copper-fin II/IIE Boiler and Water Heater Service Manual 1 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 User Access Installer Access Sub See Menu Description Item Page Display Modify Display Modify 1 BMS Type 23 No No Yes Yes 2 Voltage at Minimum (V at Min) 23 No No Yes Yes 3 Voltage at Maximum (V at Max) 23 No No Yes Yes 4
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Copper-fin II/IIE Boiler and Water Heater Service Manual 1 Service (continued) Viewable and changeable control parameters Before changing parameters, note the Example: Monday ON: 22:30, Tuesday OFF: 6:45. If you wish CAUTION settings so that the unit can be returned to to skip a day and have no night setback, set the on and off times its original operating parameters. 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
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Copper-fin II/IIE Boiler and Water Heater Service Manual 1 Service SH Maximum setpoint (boiler only) Ignition attempts The SH maximum setpoint sets the maximum water temperature The burner cycles parameter shows the total number of times setpoint that can be used for space heating. The user or installer the unit has attempted to fire. will not be able to program the control with a higher SH setpoint. The temperature range of this parameter is 32°F (0°C) Last 10 lockouts to 230°F (110°
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Copper-fin II/IIE Boiler and Water Heater Service Manual 1 Service (continued) Freeze protection pump on DHW/SH switching time (boiler only) In order to prevent the water in the heater from freezing, the The time that the SMART SYSTEM control services a DHW SMART SYSTEM control turns on the boiler pump whenever demand before returning to the SH demand is set by this the inlet temperature goes below the minimum temperature. parameter. The range of this parameter is 0 to 240 minutes.
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Copper-fin II/IIE Boiler and Water Heater Service Manual 1 Service Figure 1-1_Outdoor Air Reset Curve Maximum SH setpoint Outdoor air reset (boiler only) Outdoor air reset operation When the outdoor temperature drops to its minimum setting (F1) the water temperature setpoint will be at this When the outdoor air sensor is installed, the control will value, if the SH setpoint is set higher (FIG. 1-1). The calculate the water temperature setpoint based on the outdoor temperature range of
