Lochinvar 500 Manuel utilisateur

Service Manual

Models: 400, 500, 600, 725, & 850

This manual must only be used

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.

WARNING

Save this manual for future reference.

FTXL-SER Rev A

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 situation which, if not avoided, will result in death or serious

injury.

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious

injury.

CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate

injury.

CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not

avoided, may result in property damage.

NOTICE indicates special instructions on installation, operation, or maintenance that are important but not

related to personal injury or property damage.

CONTENTS........................................................................ 2

Hazard Definitions.............................................................. 2

PLEASE READ BEFORE PROCEEDING ........................ 3

Handling Ceramic Fiber Materials...................................... 3

When servicing boiler................................................... 4

Boiler operation............................................................ 4

Boiler water................................................................... 4

Freeze protection fluids................................................ 4

WHAT IS IN THIS MANUAL.............................................. 5

1. SERVICE

Near Boiler Piping.............................................................. 6

The FTXL Display .............................................................. 7

Control Inputs ............................................................... 8

Control Outputs............................................................. 9

General Operation...................................................... 10

Sequence of Operation............................................... 11-12

Display Panel Menu Access ............................................ 13

Display Panel Parameter Access................................ 14-15

Parameter Table.......................................................... 16-19

Viewable and Changeable Control Parameters.......... 20-30

2. MAINTENANCE

Maintenance and Annual Startup................................ 31-36

3. TROUBLESHOOTING

Before Troubleshooting.................................................... 37

Check Control Module Fuses .......................................... 37

Table 3-1 - Troubleshooting Chart - No Display.............. 38

Checking Temperature Sensors ...................................... 39

Table 3-3 - Troubleshooting Chart - Noisy System ......... 40

Table 3-4 - Troubleshooting Chart - Fault Messages. 41-47

Combustion Analysis Procedure................................. 47-48

Table 3-5 - Flue Products ................................................ 48

Table 3-6 - Troubleshooting Chart - Combustion Levels 48

Gas Valve Adjustment Procedure.................................... 49

Revision Notes.................................................. Back Cover

Contents

Service Manual

Please read before proceeding

Installer – Read all instructions, including

this manual and the FTXL Installation

and Operation Manual, before installing.

Perform steps in the order given.

User – This manual is for use only by

a qualified heating installer/service

technician. Refer to the FTXL User’s

Information Manual for your reference.

Have this boiler serviced/inspected by

a qualified service technician at least

annually.

Failure to comply with the above could

result in severe personal injury, death or

substantial property damage.

When calling or writing about the boiler

– Please have the boiler model and serial

number from the boiler rating plate.

Consider piping and installation when

determining boiler location (see the FTXL

Installation and Operation Manual).

Any claims for damage or shortage

in shipment must be filed immediately

against the transportation company by the

consignee.

Handling ceramic fiber materials

REMOVAL OF COMBUSTION CHAMBER LINING

The combustion chamber insulation in this appliance contains ceramic fiber material. Ceramic fibers

can be converted to cristobalite in very high temperature applications. The International Agency for

Research on Cancer (IARC) has concluded, “Crystalline silica inhaled in the form of quartz or cristobalite

from occupational sources is carcinogenic to humans (Group 1).” Normal operating temperatures in this

appliance are below the level to convert ceramic fibers to cristobalite. Abnormal operating conditions

would have to be created to convert the ceramic fibers in this appliance to cristobalite.

The ceramic fiber material used in this appliance is an irritant; when handling or replacing the ceramic

materials it is advisable that the installer follow these safety guidelines.

Avoid breathing dust and contact with skin and eyes.

• Use NIOSH certified dust respirator (N95). This type of respirator is based on the OSHA

requirements for cristobalite at the time this document was written. Other types of respirators may

be needed depending on the job site conditions. Current NIOSH recommendations can be found on

the NIOSH website at http://www.cdc.gov/niosh/homepage.html. NIOSH approved respirators,

manufacturers, and phone numbers are also listed on this website.

• Wear long-sleeved, loose fitting clothing, gloves, and eye protection.

Apply enough water to the combustion chamber lining to prevent airborne dust.

Remove the combustion chamber lining from the appliance and place it in a plastic bag for disposal.

Wash potentially contaminated clothes separately from other clothing. Rinse clothes washer thoroughly.

NIOSH stated First Aid.

Eye: Irrigate immediately.

Breathing: Fresh air.

WARNING NOTICE

WARNING

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.

• Should overheating occur or gas supply fail to shut off,

do not turn off or disconnect electrical supply to

circulator. Instead, shut off the gas supply at a location

external to the appliance.

• Do not use this boiler if any part has been under water.

The possible damage to a flooded appliance can be

extensive and present numerous safety hazards. Any

appliance that has been under water must be replaced.

Boiler water –

• Thoroughly flush the system (without boiler

connected) to remove sediment. The high-efficiency

heat exchanger can be damaged by build-up or

corrosion due to sediment.

• Do not use petroleum-based cleaning or sealing

compounds in the boiler system. Gaskets and seals in

the system may be damaged. This can result in

substantial property damage.

• Do not use “homemade cures” or “boiler patent

medicines”. Serious damage to the boiler, personnel,

and/or property may result.

• Continual fresh make-up water will reduce boiler life.

Mineral buildup in the heat exchanger reduces heat

transfer, overheats the stainless steel heat exchanger, and

causes failure. Addition of oxygen carried in by makeup

water can cause internal corrosion. Leaks in boiler

piping must be repaired at once to prevent the

introduction of makeup water.

Freeze protection fluids –

• NEVER use automotive antifreeze. Use only inhibited

propylene glycol solutions which are specifically

formulated for hydronic systems. Ethylene glycol is

toxic and can attack gaskets and seals used in hydronic

systems.

Service Manual

What is in this manual?

Service

Near boiler piping

• Typical system components

The FTXL 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 boiler operates

• How the control module operates

• Access modes -- user and installer

• Sequence of operation -- Domestic Hot Water

(DHW)/space heating

Control panel menu access

• Accessing programming mode and locating menus

(See separate guide covering the interface.)

Control panel parameter access

• Accessing and changing parameters from the display panel

Quick start information -- parameter

table

• An index of available adjustments and readouts, where to

access them and where to find detailed information.

FTXL parameters

• General

• Temperature Setting

• Data Logging

• Functions

• DHW Settings

• Outdoor Reset

• Anti-cycling

• Control Modes

• Building Management System (BMS)

• Circulation Pumps

• Service Notification

• Basic Setup

• USB

Maintenance

• Service and maintenance schedules

• Address reported problems

• Inspect boiler area and boiler interior

• Clean condensate trap

• Check all piping for leaks

• Check air openings

• Flue vent system and air piping

• Check water system

• Check expansion tank

• Check boiler relief valve

• Inspect ignition electrode

• Check ignition ground wiring

• Check all boiler wiring

• Check control settings

• Perform start-up and checks

• Check burner flame

• Check flame signal

• Check flue gas temperature

• General maintenance

• Review with owner

• Cleaning boiler heat exchanger

• Oiled bearing circulators

Troubleshooting

• Troubleshooting table - No display

• Checking temperature sensors

• Sensor tables

• Troubleshooting table - Fault messages displayed on

boiler interface

• Combustion analysis procedure

• Gas valve adjustment procedure

Service Manual

1 Service

IMG00996

FROM

SYSTEM TO

SYSTEM

SYSTEM PUMP

SYSTEM SUPPLY SENSOR

DIRT SEPARATOR

Y-STRAINER

(RECOMMENDED)

BOILER PUMP

INDIRECT

DOMESTIC

HOT WATER

TANK

TO DRAIN

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.

Service Manual

1 Service (continued)

IMG01093

USB

DRIVE

CONNECTION

NAVIGATION

DIAL

LEFT

SELECT KEY

RESET

SWITCH

RIGHT

SELECT KE

The FTXL display

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

SHDN = Right SELECT Key

Service Manual

1 Service

GAS PRESSURE SWITCH

DHW THERMOSTAT

ROOM THERMOSTAT /

ZONE CONTROL

FLOW SWITCH

SYSTEM SUPPLY SENSOR

OUTDOOR SENSOR

SEQUENCER / BUILDING

MANAGMENT SYSTEM

LOW VOLTAGE

CONNECTION

BOARD

INLET TEMPERATURE

SENSOR

OUTLET TEMPERATURE /

HI-LIMIT SENSOR

FLUE GAS SENSOR

LOUVER PROVING SWITCH

FLAME SENSOR

LOW WATER CUTOFF

BLOCKED DRAIN SWITCH

DISPLAY PANEL

SMART CONTROL

MODULE

SYSTEM PUMP SPEED CONTROL

IMG00006

DHW RECIRCULATION SENSOR

USB1

USB2

Reset

Control inputs

Service Manual

1 Service

1 Service (continued)

LOW VOLTAGE

CONNECTION

BOARD

SMART CONTROL

MODULE

ALARM BELL

LOUVER RELAY

RUN TIME CONTACTS

BUILDING MANAGEMENT

SYSTEM

BOILER PUMP

SYSTEM PUMP

DHW PUMP

IGNITOR

BLOWER

GAS VALVE

DISPLAY PANEL

DHW RECIRCULATION

PUMP RELAY

USB 1

USB 2

Reset

FLUE DAMPER RELAY

BACKFLOW PREVENTER

Control outputs

Service Manual

1 Service

General Operation

How the boiler operates

The FTXL uses an advanced stainless steel heat exchanger

and an electronic control module that allows fully

condensing operation. The blower pulls in gas and air and

pushes flue products out of the boiler through the heat

exchanger and flue piping. The control module regulates

blower speed to control boiler firing rate. The gas valve

senses the amount of air flowing into the boiler and allows

only the right amount of gas to flow.

How the control module operates

The FTXL control module receives input from boiler

sensors. The control module activates and controls the

blower and gas valve to regulate heat input and switches

boiler, DHW, DHW recirculation, and system pumps on

and off as needed. The user/installer programs the module

to meet system needs by adjusting control parameters.

These parameters set operating temperatures and boiler

operating modes. Boiler operation can be based on boiler

outlet water temperature, boiler return water temperature

or system supply temperature, depending on the parameter

setting.

Sequence of operation

Table 1-1 shows control module normal sequences of

operation for space heating and DHW operation. The

combined operation sequence is for a typical application,

programmed to provide DHW priority.

Access modes

User

The user can adjust space heating and tank target temperatures

by pressing the NAVIGATION dial when “SETPOINTS” is

flashing at the bottom of the display. The date and time, and

the temperature units can also be changed.

Installer

Most parameters are available only to the installer, accessible

by entering the installer password (5309).

Saving parameters (reference the Parameter Table -

Table 1-4 on pages 16 - 19 of this manual)

Please note that the brackets ([]) denote

screen status.

NOTICE

To save parameters and exit programming:

Press the RIGHT SELECT [SAVE] key and then press the

RIGHT SELECT [HOME] key.

To enter a parameter and continue programming:

Press the RIGHT SELECT [SAVE] key 1 time to return to the

parameter listings; press again to return to the menu listings.

Remember to press the RIGHT SELECT [HOME] key when

finished programming in order to save the changes made.

Service Manual

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