Lochinvar FTxl 500 Service Manual
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Lochinvar FTxl 500 Service Manual

Lochinvar FTxl 500 Service Manual

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See also: Operation & Installation Manual
FTXL-SER Rev A
Service Manual
Models: 400, 500, 600, 725, & 850
This manual must only be used
WARNING
by a qualified heating installer
/ service technician. Read all
instructions,
including
this
manual and the FTXL 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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Summary of Contents for Lochinvar FTxl 500

  • Page 1 FTXL-SER Rev A Service Manual Models: 400, 500, 600, 725, & 850 This manual must only be used WARNING by a qualified heating installer / service technician. Read all instructions, including this manual and the FTXL Installation and Operation Manual, before installing.

  • Page 2: Table Of Contents

    Contents 2. MAINTENANCE CONTENTS ................ 2 Maintenance and Annual Startup ........ 31-36 Hazard Definitions .............. 2 3. TROUBLESHOOTING PLEASE READ BEFORE PROCEEDING ......3 Before Troubleshooting ............ 37 Handling Ceramic Fiber Materials ........3 Check Control Module Fuses .......... 37 When servicing boiler ...........

  • Page 3: Please Read Before Proceeding

    Service Manual Please read before proceeding Installer – Read all instructions, including When calling or writing about the boiler WARNING 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 The FTXL display • Clean condensate trap • 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 SYSTEM 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 DRIVE RESET CONNECTION SWITCH LEFT SELECT KEY RIGHT SELECT KEY NAVIGATION DIAL IMG01093 The information on the bottom of the display shows the functions of the two SELECT keys (on either corner), and the NAVIGATION dial (in the center): MENU = Left SELECT Key SETPOINTS = NAVIGATION Dial - Pressing Down...

  • 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 SYSTEM SUPPLY SENSOR OUTDOOR SENSOR SEQUENCER / BUILDING MANAGMENT SYSTEM LOW WATER CUTOFF LOUVER PROVING SWITCH INLET TEMPERATURE SENSOR...

  • 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 USB 1...

  • Page 10: General Operation

    Service Manual Service Service General Operation Access modes How the boiler operates User The user can adjust space heating and tank target temperatures The FTXL uses an advanced stainless steel heat exchanger by pressing the NAVIGATION dial when “SETPOINTS” is and an electronic control module that allows fully flashing at the bottom of the display.
  • Page 11 Service Manual Service (continued) Table 1-1 Sequence of Operation OPERATION DISPLAY 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 Service Manual Service Table 1-1 (continued from previous page) Sequence of Operation OPERATION DISPLAY 7. If flame is detected, it holds the firing rate steady for a few seconds to let the flame stabilize, then it begins to modulate the firing rate based on a set point or some other command (such as a 0-10V BMS signal).

  • Page 13: Display Panel Menu Access

    Service Manual Service Service (continued) Display panel menu access Table 1-2 Use this procedure to access menus from the display panel SCREEN BUTTON OPERATION DISPLAY STATUS Press and hold the LEFT SELECT soft key [MENU] [MENU] for five (5) seconds. Rotate the NAVIGATION dial clockwise until 5 is displayed (first digit on the left).

  • Page 14: Display Panel Parameter Access

    Service Manual Service Service Display panel parameter access Table 1-3 This is a typical example of accessing a parameter, shown for parameter Temperature Settings, MIN SH Setpt SCREEN BUTTON OPERATION DISPLAY STATUS This example shows how to access parameter Temperature Settings. The first display shown is at the beginning of the menu listings, after entering the installer access code.
  • Page 15 Service Manual Service (continued) Display panel parameter access (cont.) Table 1-3 This is a typical example of accessing a parameter, shown for parameter Temperature Settings, MIN SH Setpt SCREEN BUTTON OPERATION DISPLAY STATUS This example shows how to access parameter Temperature Settings. The first display shown is at the beginning of the menu listings, after entering the installer access code.

  • Page 16: Parameter Table

    Service Manual Service Service Parameter table Table 1-4 This table lists SMART SYSTEM control module parameters and where to access them Installer Menu Description User Access Page Access Vacation Mode (On/Off) Time and Date Software Version (read only) Temperature Units (ºC/ºF) SH Night Setback Offset IF SH NSB >...
  • Page 17 Service Manual Service Service (continued) Parameter table Table 1-4 (continued from previous page) This table lists SMART SYSTEM control module parameters and where to access them Installer Menu Description User Access Page Access Tank Minimum Set Point Tank Maximum Set Point DHW Max Rate DHW Type (normal, zone) i.
  • Page 18 Service Manual Service Parameter table Table 1-4 (continued from previous page) This table lists SMART SYSTEM control module parameters and where to access them Installer Menu Description User Access Page Access Anti-cycling Time Anti-cycling Override Differential Ramp Delay (Enable/Disable) Modulation Factor Controlling Sensor(Outlet/System Supply/Inlet) Cascade Address IF Address = 0:...
  • Page 19 Service Manual Service (continued) Parameter table Table 1-4 (continued from previous page) This table lists SMART SYSTEM control module parameters and where to access them Installer Menu Description User Access Page Access System Pump Delay Boiler Pump Delay DHW Pump Delay System Pump Anti-Seize Delay Boiler Pump Anti-Seize Delay DHW Pump Anti-Seize Delay...

  • Page 20: Viewable And Changeable Control Parameters

    Service Manual Service Viewable and changeable control parameters Before changing parameters, note the NOTE: The DHW night setback will not work without a tank CAUTION settings so that the unit can be returned to sensor installed. its original operating parameters. The installer may adjust the space heating night setback offset General by accessing the SH Night Setback Offset parameter and the...

  • Page 21: Temperature Settings

    This The optional Lochinvar Multi-Temperature Loop Control parameter can be changed by accessing the Display Contrast Board (MTLC) can be used to control the supply temperature setting.
  • Page 22 Service Manual Service Functions DHW Settings Service Mode Delay DHW Tank Set Point By pressing the pin button on the front of the display for By installing a tank sensor, the SMART SYSTEM control can five (5) seconds, the control will be placed in Service Mode. perform the tank thermostat function.

  • Page 23: Outdoor Reset

    Service Manual Service (continued) Tank Minimum Set Point DHW/SH Switching Time When a boiler has a DHW demand and it receives a space This setting controls the minimum tank set point for the tank heating demand, the SMART SYSTEM control will start a temperature.
  • Page 24 Service Manual Service Figure 1-1 Outdoor Air Reset Curve SET POINT AT LOW OUTDOOR TEMPERATURE (SH) SET POINT SET POINT AT HIGH OUTDOOR TEMPERATURE HIGH OUTDOOR TEMPERATURE LOW OUTDOOR TEMPERATURE Set Point (1 - 3) at Low Outdoor Temperature Outdoor Air Shutdown (SH1 - SH3) When the outdoor air temperature drops to the Outdoor When the outdoor temperature rises above this point, the (1 - 3) Low parameters, the calculated set point will be at...
  • Page 25 Service Manual Service (continued) Anti-Cycling Boost Temperature If a SH demand lasts longer than the programmed time Anti-Cycling Time delay setting and there have been no DHW demands, the Once the burner turns off, a set amount of time must elapse control will increase the water temperature set point by the before the control will respond to a new demand.
  • Page 26 Service Manual Service Ramp Settings Maximum Cascade Set Point This parameter determines the set point used by the individual Please note that the brackets ([]) denote NOTICE boilers in a Cascade when a system sensor is connected to the screen status. Leader boiler.
  • Page 27 Service Manual Service (continued) Alternate Leader As the calculated load increases further and both boilers ramp up to 100%, it lowers the rate of the first two (2) This parameter allows the Member 1 boiler to automatically boilers to 67% and brings the next boiler on at 67%. The assume control of the Cascade should it lose communication three (3) boilers then modulate together.
  • Page 28 Service Manual Service Building Management System (BMS) Volts at Minimum When programmed for BMS control through the 0 - 10V BMS input or through ModBus/BACnet, the Volts at The set point or modulation of the boiler may be controlled Minimum parameter should be set to the minimum voltage through the 0 - 10V BMS input, BACnet, or ModBus.

  • Page 29: Circulation Pumps

    Service Manual Service (continued) System Pump Type The system pump can be programmed to operate in response BAS T/O to any of the Room Thermostat inputs, or to run continuously This is the amount of time the unit controls will wait to until all three (3) SH demands go into Outdoor Shutdown.
  • Page 30 When a Maintenance Reminder timer or counter has expired, “lochinvar”. If it does not find it, the display will ask if you a Maintenance Reminder screen will appear on the display.

  • Page 31: 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 32: Inspect Boiler Area

    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 33: Check Expansion Tank

    Service Manual Maintenance (continued) Flue vent system and air piping Safety relief valves should be re-inspected WARNING AT LEAST ONCE EVERY THREE YEARS, Visually inspect the entire flue gas venting system and air by a licensed plumbing contractor or piping for blockage, deterioration or leakage. Repair any authorized inspection agency, to ensure joints that show signs of leakage.

  • Page 34: Check Burner Flame

    Service Manual Maintenance 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 35: Check Flame Signal

    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 36 Service Manual Maintenance Test low water flow conditions Figure 2-3 Adjust outlet isolation valve This test is to be carried out once ADJUST OUTLET NOTICE the FTXL boiler is completely piped ISOLATION VALVE ONLY in with adequate gas and water flow. Once the test is completed, ensure that the isolation valve is opened up to allow full water flow.

  • Page 37: 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 38: Corrective Action

    Service Manual Troubleshooting 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 39: Checking Temperature Sensors

    Service Manual Troubleshooting (continued) 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 40 Service Manual Troubleshooting Table 3-3 Troubleshooting Chart - Noisy System FAULT CAUSE CORRECTIVE ACTION Supply problem. Natural • Refer to Section 7 - Gas Connections of the pressures should be between 4 inches FTXL Installation and Operation Manual for detailed w.c.
  • Page 41 Service Manual Troubleshooting (continued) Table 3-4 Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION • Measure the supply gas pressure to determine cause of failure. Natural gas pressures should be between 4 - 14 inches w.c. and LP gas pressures should be between 8 - 14 inches w.c.
  • Page 42 Service Manual Troubleshooting 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 set time period. The burner recently turned off. Anti-cycling •...
  • Page 43 Service Manual Troubleshooting (continued) Table 3-4 (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION Flame Sequence • Check supply voltage for proper polarity. (will require a manual • Check external wiring for voltage feedback. reset once the condition The flame detector circuit is seeing a flame has been corrected.
  • Page 44 Service Manual Troubleshooting Table 3-4 (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION • If 120 vac is present on a call for heat and the boiler pump is not operating, replace the pump. Outlet MRHL •...
  • Page 45 Service Manual Troubleshooting (continued) Table 3-4 (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION Louver Proving • Check function of remote devices. (will require a manual reset An optional remote proving switch is not once the condition has been making.
  • Page 46 Service Manual Troubleshooting Table 3-4 (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION • Inspect the heat exchanger. Reference page 35 of this manual for the procedure on how to clean the flue side of the heat exchanger.

  • Page 47: Combustion Analysis Procedure

    Service Manual Troubleshooting (continued) Table 3-4 (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION • Check 120 vac supply to the transformer. • Check wiring connections at the low voltage terminal 120 vac input to the main control board has Low 24 vac strip.
  • Page 48 Service Manual Troubleshooting Table 3-5 Flue Products Natural Gas Propane 8.0% - 10% 3.0% - 6.5% 9.0% - 11% 4.1% - 6.9% 7. Once the boiler has modulated up to full fire, measure the combustion. The values should be in the range listed in Table 3-5.

  • Page 49: Gas Valve Adjustment Procedure

    Service Manual Troubleshooting (continued) Gas valve adjustment procedure Models 600 - 850 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 (ECO #C15743) initial release. FTXL-SER Rev A 07/14...

This manual is also suitable for:

Ftxl 400Ftxl 600Ftxl 725Ftxl 850400600 ... Show all

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