Lochinvar FTXL 400 Series Service Manual
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Lochinvar FTXL 400 Series Service Manual

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Service Manual
Models: 400 - 850 SERIES 120 &
1000 SERIES 110
2000611019 00
This manual must only be used
WARNING
⚠ WARNING
⚠
This manual must only be used by
by a qualified heating installer
a qualified heating installer / service
/ service technician. Read all
technician. Read all instructions,
instructions,
including this manual and the
manual and the FTXL Installation
FTXL Installation and Operation
and Operation Manual, before
Manual, before installing. Perform
installing. Perform steps in the
steps in the order given. Failure
order given. Failure to comply
to comply could result in severe
could result in severe personal
personal injury, death, or substantial
injury, death, or substantial
property damage.
property damage.
Save this manual for future reference.
Save this manual for future reference.
100369173_2000625608 Rev A
including
this

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Summary of Contents for Lochinvar FTXL 400 Series

  • Page 1 100369173_2000625608 Rev A Service Manual Models: 400 - 850 SERIES 120 & 1000 SERIES 110 2000611019 00 This manual must only be used WARNING ⚠ WARNING ⚠ This manual must only be used by by a qualified heating installer a qualified heating installer / service / service technician.

  • Page 2: Table Of Contents

    Contents 2. MAINTENANCE CONTENTS ............... 2 Maintenance and Annual Startup ........ 29-34 Hazard Definitions .............. 2 3. TROUBLESHOOTING PLEASE READ BEFORE PROCEEDING ..... 3 Before Troubleshooting ............ 35 Handling Ceramic Fiber Materials ........3 Check Control Module Fuses .......... 35 When servicing boiler ...........

  • Page 3: Please Read Before Proceeding

    Service Manual Please read before proceeding Installer – Read all instructions, including ⚠ WARNING When calling or writing about the boiler NOTICE this manual and the FTXL Installation – Please have the boiler model and serial and Operation Manual, before installing. number from the boiler rating plate.

  • Page 4: When Servicing Boiler

    Service Manual Please read before proceeding When servicing boiler – • To avoid electric shock, disconnect electrical supply before performing maintenance. • To avoid severe burns, allow boiler to cool before performing maintenance. Boiler operation – • Do not block flow of combustion or ventilation air to the boiler.

  • Page 5: What Is In This Manual

    Service Manual What is in this manual? Service Maintenance Near boiler piping • Service and maintenance schedules • Address reported problems • Typical system components • Inspect boiler area and boiler interior • Clean condensate trap The FTXL display • Check all piping for leaks •...

  • Page 6: Service Near Boiler Piping

    Service Manual Service Near boiler piping This piping reference is included to specify the Near Boiler Piping specific to the FTXL. This piping scheme is important for proper operation of the SMART TOUCH control. See the FTXL Installation and Operation Manual for more detailed piping diagrams.

  • Page 7: The Ftxl Display

    Service Manual Service (continued) The FTXL display HOME VIEW SETUP INFORMATION SETTINGS...

  • Page 8: Control Inputs

    Service Manual Service Service Control inputs DHW RECIRCULATION SENSOR SYSTEM PUMP SPEED CONTROL GAS PRESSURE SWITCH DHW THERMOSTAT ROOM THERMOSTAT / ZONE CONTROL LOW VOLTAGE CONNECTION FLOW SWITCH BOARD DHW RECIRCULATION SENSOR SYSTEM SUPPLY SENSOR OUTDOOR SENSOR SEQUENCER / BUILDING MANAGMENT SYSTEM LOW WATER CUTOFF LOUVER PROVING SWITCH...

  • Page 9: Control Outputs

    Service Manual Service Service (continued) Control outputs DHW RECIRCULATION PUMP RELAY ALARM BELL LOW VOLTAGE LOUVER RELAY CONNECTION BOARD RUN TIME CONTACTS BUILDING MANAGEMENT SYSTEM BOILER PUMP SYSTEM PUMP DHW PUMP IGNITOR BACKFLOW PREVENTER BLOWER SMART CONTROL MODULE GAS VALVE FLUE DAMPER RELAY DISPLAY PANEL 2000610804 00...

  • Page 10: General Operation

    Service Manual Service Service General Operation How the boiler operates Adjust set point temperature(s) During normal operation, set point temperatures can be The FTXL uses an advanced stainless steel heat exchanger adjusted from the Home Screen by pressing the DETAILS and an electronic control module that allows fully button on the bottom of the screen (see FIG.

  • Page 11: Sequence Of Operation

    Service Manual Service Service (continued) Table 1-1 Sequence of Operation OPERATION 1. Upon a call for heat, the gas pressure switch(es) must be closed. 2. Once the gas pressure switch(es) are closed, the control turns on the appropriate pumps (system and boiler pumps for space heating, DHW pump for DHW).

  • Page 12: Display Panel Menu Access

    Service Manual Service Service (continued) Display panel menu access...

  • Page 13: Parameter Table

    Service Manual Service Service (continued) Parameter table Table 1-2 This table lists SMART TOUCH control module parameters and where to access them User Access Installer Access Menu Description Display Modify Display Modify Time and Date Software Version (read only) Temperature Units (ºC/ºF) SH Night Setback Offset SH Night Setback On Times SH Night Setback Off Times...
  • Page 14 Service Manual Service Service Parameter table Table 1-2 (continued from previous page) This table lists SMART TOUCH control module parameters and where to access them User Access Installer Access Menu Description Display Modify Display Modify Outdoor 1 Low Outdoor 1 High Set Point 1 at Low Outdoor Temp 1 Set Point 1 at High Outdoor Temp 1 Outdoor Air Shutdown SH1...
  • Page 15 Service Manual Service (continued) Parameter table Table 1-2 (continued from previous page) This table lists SMART TOUCH control module parameters and where to access them User Access Installer Access Menu Description Display Modify Display Modify Controlling Sensor BMS Tstat Input ModBus ModBus T/O Cascade Address...

  • Page 16: Initial Setup

    (4) hours. This parameter must be accessed to set the clock. If the unit is connected to the internet, the Press the SETTINGS button under the Lochinvar logo time will adjust based on the time zone selected.

  • Page 17: Viewable And Changeable Control Parameters

    Service Manual Service Viewable and changeable control parameters Before changing parameters, note the settings so that the unit can be returned to its original operating CAUTION parameters. Set Point Screens Figure 1-2 Set Points HW Screen Space Heating (SH) and Domestic Hot Water (DHW) Space Heating (SH) and Domestic Hot Water (DHW) Night Setback Offset Night Setback On &...
  • Page 18 (continued) Display Timeout 3-Way Valve Time The optional Lochinvar Multi-Temperature Loop Control This is the time in which the display remains illuminated. Board (MTLCB) can be used to control the supply temperature The range is 10 seconds to 10 minutes. The default is 3 up to three (3) sub-loops, corresponding to each of the three minutes.
  • Page 19 Service Manual Service Freeze Protection Burner Differential Once this timer expires, it will switch back to the DHW demand. The installer can adjust the length of time the boiler will service Once the burner has started firing due to a low inlet the space heating demand by accessing SH/DHW Switching temperature, the inlet temperature must increase by this Time parameter.
  • Page 20 Service Manual Service (continued) Outdoor Reset Set Point (1 - 3) at Low Outdoor Temperature When the outdoor air temperature drops to the Outdoor The option of controlling up to three (3) different outdoor (1 - 3) Low parameters, the calculated set point will be at resets for low outdoor temperatures is available.
  • Page 21 Service Manual Service Outdoor Air Shutdown Differential (SH1 - SH3) Boost Time The outdoor air shutdown differential parameter is the The boost time parameter sets the amount of time that must number of degrees below Outdoor Air Shutdown SH1, SH2, elapse with a SH demand before the water temperature and SH3 parameters the outdoor air temperature must calculated set point will be increased.
  • Page 22 Service Manual Service (continued) Ramp Settings The SMART TOUCH control can be programmed to limit the firing rate for a fixed period of time at the start of a space heating demand. There are six (6) possible limits, each with their own time delay.
  • Page 23 Service Manual Service Control modes Cascade Address The boiler designated as the Leader needs to be programmed Controlling Sensor with address 0. All the Member boilers require addresses from The SH controlling sensor parameter selects the sensor the 1 to 7, and the addresses must be different for each Member. control will use to regulate the boiler firing rate.
  • Page 24 Service Manual Service supply sensor to the user set point. If any of the boiler outlet The other Cascade divider method is Efficiency Optimization, designated as EFF in the menu. This method is used, as the temperatures reach the maximum cascade set point, the boiler will then modulate down on its own in order to keep its outlet name implies, when it is desired to have the most efficient temperature within the maximum cascade set point.
  • Page 25 Service Manual Service Figure 1-7 Cascade Leader Setup Figure 1-8 Cascade Member Setup Screen...
  • Page 26 SMART TOUCH Controls for Multiple Size Units & Front End program the system pump to run continuously until outdoor Loading Instruction Sheet provided on the Lochinvar website). shutdown starts, set the System Pump Type parameter to WWSD. The default setting is CFH.
  • Page 27 Service Manual Service (continued) Set Point at Maximum Volts System Pump Anti-Seize Delay If the boiler pump does not run for 24 hours, it will be turned When programmed for BMS control through the 0 - 10V BMS on briefly to prevent it from seizing. The length of time it runs input or through ModBus and the BMS Type is programmed as is determined by the System Pump Anti-Seize Delay parameter.
  • Page 28 Service Manual Service Figure 1-9 Service Notification Screen Table 1-3 Service Notification (This table lists control module parameters; use the sub-tab under the Setup tab to access them. Default Parameter Name Menu (as shown on the LCD screen) Value Value Value Maintenance Notice By: Months Maintenance Notice By: Running Hours...

  • Page 29: Maintenance

    Service Manual Maintenance Maintenance and annual startup Table 2-1 Service and Maintenance Schedules Owner maintenance Service technician (see the FTXL User’s Information Manual for (see the following pages for instructions) instructions) General: • Address reported problems • Check boiler area •...
  • Page 30 Service Manual Maintenance Follow the Service and maintenance procedures given throughout this manual and in component literature ⚠ WARNING shipped with the boiler. Failure to perform the service and maintenance could result in damage to the boiler or system. Failure to follow the directions in this manual and component literature could result in severe personal injury, death, or substantial property damage.
  • Page 31 Service Manual Maintenance (continued) Check boiler relief valve Flue vent system and air piping Visually inspect the entire flue gas venting system and air 1. Inspect the relief valve and lift the lever to verify flow. piping for blockage, deterioration or leakage. Repair any Before operating any relief valve, ensure that it is piped joints that show signs of leakage.
  • Page 32 Service Manual Maintenance (continued) Inspect ignition and flame sense Check burner flame electrodes 1. Inspect flame through observation window. 1. Remove the ignition and flame sense electrodes from the 2. If the flame is unsatisfactory at either high fire or low fire, boiler heat exchanger access cover.
  • Page 33 Service Manual Maintenance (continued) Check flame signal 7. Disconnect the condensate hose from the condensate trap and route to drain. 1. At high fire the flame signal shown on the display should 8. Use a vacuum cleaner to remove any accumulation on the be at least 10 microamps.
  • Page 34 Service Manual Maintenance (continued) Test low water flow conditions While slowly shutting off the isolation valve, refer to the Status Screens to watch the behavior of the boiler. These screens allow you to monitor the inlet temperature, outlet This test is to be carried out once NOTICE temperature, and ΔT.

  • Page 35: Troubleshooting

    Service Manual Troubleshooting Check control module fuses Label all wires prior to disconnection WARNING ⚠ when servicing controls. Wiring errors can cause improper and dangerous ALWAYS check control module fuses before NOTICE operation. Always disconnect power replacing control module or any major to the boiler before servicing.
  • Page 36 Service Manual Troubleshooting (continued) Table 3-1 Troubleshooting Chart - No Display FAULT CAUSE CORRECTIVE ACTION • Check external line switch, fuse, or breaker. - No 120 vac supplied to unit. • Check position of ON/OFF switch. Turn switch to the ON position.

  • Page 37: Checking Temperature Sensors

    Service Manual Troubleshooting Checking temperature sensors The boiler temperature sensors (inlet water, outlet water, system 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.
  • Page 38 Service Manual Troubleshooting (continued) Table 3-3 Troubleshooting Chart - Noisy System FAULT CAUSE CORRECTIVE ACTION - Supply gas problem. Natural gas pressures • Refer to Section 7 - Gas Connections of the should be between 4 inches w.c. and 14 FTXL Installation and Operation Manual for detailed inches w.c.
  • Page 39 Service Manual Troubleshooting Table 3-4 Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION • Reset the pressure switches. • Measure the supply gas pressure to determine cause of failure. Natural gas pressures should be between 4 - 14 inches w.c.
  • Page 40 Service Manual Troubleshooting (continued) Table 3-4 (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION • The control board will release the call for heat after a The main control board has received a call set time period.
  • Page 41 Service Manual Troubleshooting Table 3-4 (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION • Verify that the plastic hose from the gas valve to the air inlet is connected and is not damaged. •...
  • Page 42 Service Manual Troubleshooting (continued) Table 3-4 (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION • Adjust the set point of the auto reset limit to a higher setting up to a maximum of 200°F. Reference the FTXL Installation and Operation Manual for adjusting procedures.
  • Page 43 Service Manual Troubleshooting Table 3-4 (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION • Replace the main control board if necessary. • If 120 vac is present on a call for heat and the boiler Outlet MRHL pump is not operating, replace the pump.
  • Page 44 Service Manual Troubleshooting (continued) Table 3-4 (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION • Check the sensors and their associated wiring. Sensor Shorted Repair or replace the sensor or wiring if damaged. (will require a manual reset once the condition has been Either the inlet water or outlet water...
  • Page 45 Service Manual Troubleshooting Table 3-4 (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION • Check wiring to sensor. Make sure wiring is connected and not damaged. Reconnect / repair Flue Sensor Fault wiring if necessary.
  • Page 46 Service Manual Troubleshooting (continued) Table 3-4 (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION • Inspect the heat exchanger. Reference this manual for the procedure on how to clean the flue side of the heat exchanger.
  • Page 47 Service Manual Troubleshooting Table 3-4 (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION • Check set point of the external control. • Check the wiring between the external control and the Rem Ctrl Flt External control is cycling too often.
  • Page 48 Service Manual Troubleshooting (continued) Figure 3-2 Combustion Measurement Port 6. Insert the probe from a combustion analyzer into the combustion measurement port (see FIG. 3-2). There is a stop underneath the combustion measurement port to prevent the probe from collecting condensate at the bottom of the flue collector.

  • Page 49: Gas Valve Adjustment Procedure

    Service Manual Troubleshooting (continued) Gas valve adjustment procedure Models 600 - 1000 If adjustment of the gas valve is deemed necessary, use the following procedures: (Note: The procedures below are Locate the throttle adjustment screw on top of the gas valve, model specific.) see FIG.
  • Page 50 Service Manual NOTES...
  • Page 51 Service Manual NOTES...

  • Page 52: Revision Notes

    Revision Notes: Revision A (PCP #3000055547 / CN #500041992) initial release. 100369173_2000625608_Rev A 05/23...

This manual is also suitable for:

Ftxl 850 seriesFtxl 120 seriesFtxl 1000 seriesFtxl 110 series

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