Lochinvar EcoKnight EKB235CE User manual

The EcoKnight™ range

High Efficiency Gas Fired Condensing Boilers

User & SMART SYSTEM Control Guide

Models:

EKB45CE

EKB60CE

EKB85CE

EKB115CE

EKB145CE

EKB175CE

EKB205CE

EKB235CE

INS0010 Issue No 4 | October 2010

3

1.0 USER GUIDE ............................................................................................................................................................................................................................................ 4

1.1 GENERAL REQUIREMENTS ........................................................................................................................................................................................................... 4

1.2 PROCEDURE FOR LIGHTING ........................................................................................................................................................................................................ 4

1.3 PROCEDURE FOR SHUTTING DOWN .......................................................................................................................................................................................... 4

1.4 TEMPERATURE ADJUSTMENT PROCEDURE ............................................................................................................................................................................. 4

1.4.1 CENTRAL HEATING SETPOINT ..................................................................................................................................................................................... 4

1.4.2 DHW SETPOINT ............................................................................................................................................................................................................... 4

1.5 MAINTENANCE ................................................................................................................................................................................................................................ 5

1.6 FROST PROTECTION ..................................................................................................................................................................................................................... 5

1.7 AIR SUPPLY ..................................................................................................................................................................................................................................... 5

1.8 CONDENSATE DRAIN ..................................................................................................................................................................................................................... 5

2.0 SMART SYSTEM CONTROL .................................................................................................................................................................................................................. 6

2.1 GENERAL ......................................................................................................................................................................................................................................... 6

2.2 SMART SYSTEM CONTROL PANEL .............................................................................................................................................................................................. 6

2.3 SEQUENCE OF OPERATION ......................................................................................................................................................................................................... 7

2.4 STATUS DISPLAY SCREENS ......................................................................................................................................................................................................... 8

3.0 USER SETTINGS ................................................................................................................................................................................................................................... 10

3.1 GENERAL ....................................................................................................................................................................................................................................... 10

3.2 ENTERING THE USER CODE....................................................................................................................................................................................................... 10

3.3 MENU SET A: GENERAL SETTINGS ........................................................................................................................................................................................... 10

3.3.1 BOILER MODEL .............................................................................................................................................................................................................. 10

3.3.2 USER CODE .................................................................................................................................................................................................................... 10

3.3.3 TIME & DATE .................................................................................................................................................................................................................. 11

3.3.4 SOFTWARE VERSION ................................................................................................................................................................................................... 11

3.3.5 TEMPERATURE UNITS .................................................................................................................................................................................................. 11

3.3.6 NIGHT SETBACK TEMPERATURE ............................................................................................................................................................................... 11

3.3.7 NIGHT SETBACK TIME .................................................................................................................................................................................................. 11

3.4 MENU SET B: TEMP SETTINGS ................................................................................................................................................................................................... 11

3.4.1 CH SETPOINT USER ..................................................................................................................................................................................................... 11

3.5 MENU SET C: DATA LOGGING .................................................................................................................................................................................................... 12

3.5.1 HRS. RUN CH ................................................................................................................................................................................................................. 12

3.5.2 HRS. RUN DHW .............................................................................................................................................................................................................. 12

3.5.3 IGNITION ATTEMPTS .................................................................................................................................................................................................... 12

3.5.4 LAST 10 ERRORS .......................................................................................................................................................................................................... 12

3.6 MENU SET E: DHW SETTINGS .................................................................................................................................................................................................... 12

3.6.1 DHW SETPOINT USER .................................................................................................................................................................................................. 12

3.7 MENU SET F: OUTDOOR RESET ................................................................................................................................................................................................ 12

3.7.1 OUTDOOR AIR SHUTDOWN ......................................................................................................................................................................................... 12

3.7.2 OUTDOOR AIR SHUTDOWN DIFFERENTIAL .............................................................................................................................................................. 13

3.8 EXITING USER SETTINGS MODE ............................................................................................................................................................................................... 13

4

1.0 USER GUIDE

1.1 GENERAL REQUIREMENTS

 This equipment must be installed by a competent person, registered with a H.S.E. approved

body. All installations must conform to the relevant Gas Safety and Building regulations. Health

& safety requirements must also be taken into account when installing any equipment.

 A competent person must also undertake any alterations that require the gas train or flue system

to be broken.

 Any interference with a sealed component is forbidden.

 Failure to comply with the above may lead to prosecution.

 Incorrect use may result in injury and will also invalidate the warranty

1.2 PROCEDURE FOR LIGHTING

1. Ensure that the gas inlet appliance isolating valve, provided by the installer, is in the “off” position.

2. Press the power rocker switch, positioned on the back of the appliance to bring the equipment on.

3. Press the Enter/Reset button on the Smart System control panel to initiate the burner.

4. The combustion fan should ramp up to full speed to purge the combustion chamber and then drop back

to half rate in order to light. As the gas inlet appliance isolating valve is closed, the controls should go to

a flame failure condition after four ignition attempts (EKB45CE – EKB115CE) or one ignition attempt

(EKB145CE – EKB235CE). If the above occurs correctly, open the gas inlet appliance isolating valve

and reset the unit by depressing the Enter/Reset button on the control panel.

5. The combustion fan will repeat the pre-purge procedure and attempt to light. Once a flame is

established, the LCD display will change to display the rate at which it is firing.

1.3 PROCEDURE FOR SHUTTING DOWN

To take the appliance out of service, the Enter/Reset button should be pressed. If the appliance in to be shut

down for a long period of time, the power supply should be isolated using the rocker switch on the back and the

gas supply should be isolated at the manual isolation valve.

1.4 TEMPERATURE ADJUSTMENT PROCEDURE

1.4.1 CENTRAL HEATING SETPOINT

With the boiler firing, the setpoint can be adjusted using the Up and Down buttons on the SMART SYSTEM

control panel. Once the desired setpoint is displayed, the Enter/Reset button should be pressed to store the

value.

1.4.2 DHW SETPOINT

If the stored water temperature is to be controlled by a thermostat, the setting should be adjusted on the

thermostat itself. If the stored water temperature is to be controlled by a tank sensor, the default setpoint is 65°C.

The setpoint should be adjusted to ensure that the water is stored at 60°C and distributed at 50°C within 1 (one)

minute at all outlets. Care is needed to avoid much higher temperatures because of the risk of scalding. At 50°C

the risk of scalding is small for most people, but the risk increases rapidly with higher temperatures and for longer

exposure times. The risk to young children and to those with a sensory or mobility loss will be greater. Where a

significant scalding risk has been identified, the use of thermostatic mixing valves on baths and showers should be

considered to reduce temperature, these need to be placed as close to the point of use as possible.

Should the default value need adjusting, please refer to Section 3.0 User Settings

5

1.5 MAINTENANCE

The SMART SYSTEM control has a built in timer that counts the time period, operating hours and burner initiation

cycles since the unit was last maintained. Once one of these preset values has been exceeded, the display will

show SERVICE DUE every 5 seconds. At this point, it is strongly recommended that a competent person,

preferably appointed by Lochinvar Limited, carries out the necessary maintenance work.

Details of the necessary maintenance work can be found in the Installation, Commissioning and Maintenance

Instructions.

1.6 FROST PROTECTION

If the temperature of the water at the inlet side of the heat exchanger drops below 7°C, the primary pump will be

energised. If the temperature of the water at the inlet side of the heat exchanger drops further and reaches 3°C

the burner will fire. If the temperature rises above 10°C the burner and the pump will shutdown.

1.7 AIR SUPPLY

 When installed as a conventionally flued appliance, the room in which the appliance is installed must be

ventilated.

 Blocking these vents may lead to severe injury, serious property damage or death.

 The area in which the appliance is installed should not be used to store any other materials.

1.8 CONDENSATE DRAIN

The condensate drain must not be blocked or modified in any way. If fitted with a neutralisation kit, this must be

replaced at least every 12 months to ensure correct operation. Due to its design, no further maintenance should

be necessary.

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2.0 SMART SYSTEM CONTROL

2.1 GENERAL

The Lochinvar EcoKnight™ uses the SMART SYSTEM control interface. The control panel display gives

information on set-up, system status and diagnostic data in words rather than codes.

2.2 SMART SYSTEM CONTROL PANEL

FIGURE 2.1 SMART SYSTEM CONTROL PANEL

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2.3 SEQUENCE OF OPERATION

OPERATION

DISPLAY

1. Upon a call for heat, the control turns on the appropriate

pumps (primary and secondary pumps for space

heating call; DHW pump for DHW call).

BLR: Standby

OUT: 77.4C (82)

2.

The control connects 230 VAC to the fan. The fan does

not run at this time.

 If the unit is equipped with a flow switch or low

water cut-off, it must close before the control

powers up the fan.



If the unit is equipped with a manual reset high

limit it must be closed before the control powers

up the fan.



If the unit is equipped with a gas pressure switch,

it must close at this time.

 If there is an auxiliary device connected to the

unit, the unit will then provide 24 VAC to its enable

relay. If the auxiliary device has a proving switch,

it must close before the sequence continues.

BLR: Standby

OUT: 77.4C (82)

3. The control then starts a 10 second prepurge cycle.

BLR: PREPURGE

OUT: 77.4C (82)

4. Once the prepurge cycle is complete, and the blocked

drain and auto-reset high limit are closed, the control

starts the 5-second trial for ignition by sending spark

voltage to the spark electrode and opening the gas

valve.

BLR: IGNITION

OUT: 77.4C (82)

5. If the control does not detect flame by the end of the

trial for ignition, the control performs a 10 second

postpurge. On the EKB45CE to EKB115CE models,

the control will perform another prepurge and will try to

light the burner again. If the burner does not light after

4 trials, the control will lockout for 1 hour and then try

another set of 4 trials. On the EKB145CE to

EKB235CE models the unit will lockout until manually

reset.

BLR: POSTPURGE, PREPURGE

OUT: 77.4C (82)

6.

If the control detects a flame before the trial for ignition

ends, it begins to modulate the burner in order to

maintain the set point. If the boiler lights due to a

central heating call for heat, and the ramp delay function

is active (default is inactive), the modulation will be held

to a series of increasing limits after the burner has lit.

BLR: RUN 20% RATE

OUT: 78.8C (82)

7. Once the call for heat is satisfied, the control will turn off

the burner. The fan will remain on for the 10-second

postpurge cycle. The pumps will continue to run for

their respective pump delay times, and then turn off.

BLR: POSTPURGE

OUT: 81.6C (82)

8. Primary and secondary pumps switch off.

BLR: Standby

OUT: 81.6C (82)

8

2.4 STATUS DISPLAY SCREENS

Status Display Screens

By using the Previous/Next (◄, ►) arrow keys on the SMART SYSTEM display panel, you can navigate through the six (6)

display screens. Each screen will contain two (2) viewable items. The following is a description of the individual items and

what they can display:

Screen

Display shows:

Description

1

BLR: OFF

The unit has been turned OFF by the Enter/Reset button on the SMART

SYSTEM display panel.

STANDBY

The unit has not received a call for heat from a room thermostat nor has

it received a call for heat from a tank thermostat.

SET POINT MET

The unit has met the water temperature set point, but is still receiving a

call for heat from either a room thermostat or a tank thermostat.

PREPURGE

The unit has initiated a 10 second purge period on a call for heat.

IGNITION

The unit has begun a 5 second spark period to ignite the main burner.

RUN***% RATE

The unit has fired and is running at the displayed percentage.

POSTPURGE

The call for heat has been satisfied and the unit runs the fan for an

additional 10 seconds to clear the combustion chamber and vent system

of residual flue products.

SERVICE

The unit has been placed in a temporary mode that will allow the unit to

fire at 100% of rate for the purpose of combustion analysis.

OUT:***.*C

The outlet temperature is displayed.

OPEN

The control does not detect the outlet sensor.

SHORTED

The outlet sensor wires or the sensor itself has become shorted.

Press the Next ► arrow key on the SMART SYSTEM display to access Screen 2

2

IN: ***.*C

If the inlet sensor has not been selected as the control sensor, only the

inlet temperature will be displayed.

***.*C (***)

When the inlet sensor has been selected as the control sensor, the

control will display the inlet temperature as well as the set point in

brackets.

OPEN

The control does not detect the inlet sensor

SHORTED

The inlet sensor wires or the sensor itself has become shorted.

RISE: ***.*C

The difference between the inlet temperature and the outlet

temperature.

Press the Next ► arrow key on the SMART SYSTEM display to access Screen 3.

3

SYS: ***.*C

If the system supply sensor has not been selected as the control sensor,

only the system temperature will be displayed.

***.*C (***)

When the system supply sensor has been selected as the control

sensor, the control will display the system temperature as well as the set

point in brackets.

OPEN

The control does not detect the system supply sensor

SHORTED

The system supply sensor wires or the sensor itself has become

shorted.

OUTDOOR: ***.*C

The control will display the outdoor air temperature as sensed by the

outdoor air sensor

OPEN

The control does not detect the outdoor air sensor

SHORTED

The outdoor air sensor wires or the sensor itself has become shorted.

Press the Next ► arrow key on the SMART SYSTEM display to access Screen 4.

4

FLUE: ***.*C

The control will display the flue temperature.

OPEN

The control does not detect the flue sensor.

SHORTED

The flue sensor wires or the sensor itself has become shorted.

AUX: ***.*C

The control will display the temperature.

OPEN

The control does not detect the auxiliary sensor.

SHORTED

The auxiliary sensor wires or the sensor itself has become shorted.

Press the Next ► arrow key on the SMART SYSTEM display to access Screen 5.

5

FAN SPD: ****RPM

The control will display the actual fan motor RPM.

FLAME SIG: **.*UA

The control will display the flame signal in dc micro amps.

Press the Next ► arrow key on the SMART SYSTEM display to access Screen 6.

9

6

BLR CFH: OFF

The control has not received a call for heat from a room thermostat

ON

The control has received a call for heat from a room thermostat

DHW CFH: OFF

The control has not received a DHW call for heat and has not powered

the DHW pump.

ON

The control has received a DHW call for heat.

Press the Next ► arrow key on the SMART SYSTEM display to access Screen 7.

7

DHW PUMP: OFF

The control has not received a DHW call for heat and has not powered

the DHW pump

ON

The control has received a DHW call for heat and has powered the DHW

pump

DELAY

The DHW call for heat has been satisfied and the DHW pump is running

for a fixed time to remove any residual heat.

0-10V IN: **.VDC

The control will display a 0-10Vdc signal received from a Building

Management System (BMS) connected to the unit.

Press the Next ► arrow key on the SMART SYSTEM display to access Screen 8.

8

SYS PUMP: OFF

The control has not received a call for heat from a room thermostat and

has not powered the secondary pump

ON

The control has received a call for heat from a room thermostat and has

powered the secondary pump

DELAY

The call for heat has been satisfied and the secondary pump is running

for a fixed time to remove any residual heat.

BLR PUMP OFF

The control has either not received a call for heat from a remote

thermostat, a remote thermostat is not connected to the unit and the

water temperature has not dropped below the temperature set point of

the control to initiate a call for heat, or the control has received a DHW

call for heat from a DHW thermostat.

ON

The control has either received a call for heat from a remote thermostat

or a remote thermostat is not connected to the unit and the water

temperature has not dropped below the temperature set point of the

control to initiate a call for heat.

DELAY

The call for heat has been satisfied and the primary pump is running for

a fixed time to remove any residual heat.

Press the Next ► arrow key on the SMART SYSTEM display to access Screen 9.

9

Cas: Off

The Master control has been turned off by the Enter/Reset button on the

Smart System display.

Cas: Standby

The Master boiler has not received a call for heat from a remote

thermostat.

Cas: 61.4C (65)

The Cascade is now active. The system temperature will be displayed.

The Cascade set point will be displayed in brackets.

Cas: Setpoint Met

The Cascade has met the water temperature set point, but is still

receiving a call for heat from a tank sensor.

Cas: No Members

The Master control could not detect any Member controls to participate

in the Cascade.

PMP: Off

The Master control has not received a call for heat from a tank sensor

and has not powered the DHW pump.

PMP: On

The Master control has received a call for heat from a remote thermostat

and has powered the system pump.

PMP: Delay

The tank call for heat has been satisfied and the tank pump is running

for a fixed time to remove any residual heat.

Press the Next ► arrow key on the SMART SYSTEM display to access Screen 10.

10

Cas Pow: ***% ***%

The first percentage shows the firing rate that is being sent to the last

boiler called on. The second percentage shows the total power available

to the Cascade.

Present: 01234567

Example:

Present: 23----01

Shows the number of boilers connected to the Cascade. The Master is

designated as 0. Members will be designated 1 - 7. If a “-“ is used in

place of a number, that boiler is either not connected, or in a lockout

mode and not available for the Cascade. If the number is flashing, then

that boiler is providing heat to the Cascade. As the lead boiler is

changed from day to day, that boiler’s address will be shown first in the

string of numbers. In the example, boilers 0 - 3 are present and boiler 2

is the lead boiler.

Press the Next ► arrow key on the SMART SYSTEM display to roll back to Screen 1. At any point if you wish to

access an earlier screen, press the Previous ◄ arrow key on the SMART SYSTEM display.

10

3.0 USER SETTINGS

3.1 GENERAL

Certain functions within the boiler are changeable by the user but are password protected to prevent accidental

modification. What follows is a guide showing how to access the functions and modify them.

3.2 ENTERING THE USER CODE

To access the user control the following procedure should be followed:

1. If the boiler is operating, press the Enter/Reset button to turn the unit off.

2. Press and hold the Menu/Exit button for 5 seconds. At this point the display will change to show:

Enter Menu Code:

000

3. Press the UP button 4 times. The display should now show:

0

Enter Menu Code:

000

4. Press the Previous button 2 times. The display should now show:

4

Enter Menu Code:

0004

5. Press the Up button 7 times. The display should now show:

Enter Menu Code:

0704

6. Press the Enter/Reset button. The display should now show:

Enter Menu Code:

USER CODE

3.3 MENU SET A: GENERAL SETTINGS

After 2 seconds the screen will show:

>A General

B Temp Settings

Pressing the Enter/Reset button will access the General menu set. From here, the following sub-sections can be

accessed by moving the caret symbol “>” to the appropriate line using the Up or Down buttons and then pressing

the Enter/Reset button.

3.3.1 BOILER MODEL

This is a display only parameter that will display the model name of the unit.

3.3.2 USER CODE

This setting can be used to modify the user access code. This is done using the Up, Down, Previous and Next

buttons. Once the desired code has been set, the Enter/Reset button should be pressed to save the setting.

NOTE: If this setting is modified, please make a note of the new code as it can only be reset using the computer

interface.

11

3.3.3 TIME & DATE

The control uses an internal clock for the night setback feature and for logging of events. For these features to

work correctly, the clock must be set when the boiler is first installed or anytime the boiler has been powered off

for more than 30 days.

The date and time are displayed as “YY:MM:DD W hh:mm”.

 YY = year

 MM = month

 DD = date

 W = day (1 = Sunday, 2 = Monday, etc.)

 hh = hour (24 hour time; 2:00 PM = 14:00)

 mm = minutes.

The date and time are set using the Up, Down, Previous and Next buttons. Once set, the Enter/Reset button

should be pressed to save the setting.

NOTE: The clock does not automatically adjust for Daylight Saving Times and therefore will require a manual

adjustment.

3.3.4 SOFTWARE VERSION

This is a display only parameter that will display the version number of the software loaded into the unit.

3.3.5 TEMPERATURE UNITS

The control can be configured to display the temperature units in °C of °F. The default setting is °C, to change

this, the Up or Down button should be used and the Enter/Reset button pressed to store the desired setting.

3.3.6 NIGHT SETBACK TEMPERATURE

Once the internal clock has been set correctly, the night setback feature can be used to program a lower water

temperature set point for water heating. This feature is only used when a tank sensor is used. The temperature

range for this parameter is 0°C to 60°c. The feature is turned off with a setting of 0°C. The default value is 0°C.

To modify the temperature setting, the Up or Down button should be used and the Enter/Reset button pressed to

store the desired setting.

3.3.7 NIGHT SETBACK TIME

If the Night Setback Temperature is set to anything other than 0°C, the night setback feature becomes active.

This will require start and stop times to be programmed for the days that reduced temperatures are required.

Each day of the week (Sunday through Saturday) will have an on and off time. Using the Previous and Next

buttons the desired time slot (e.g. Monday ON, Monday Off, Tuesday On etc.) can be selected. Once the desired

time slot is selected, the Up and Down buttons can be used to set the required time.

Example: Monday ON: 22:30, Tuesday OFF: 6:45. If you wish to skip a day and have no night setback, leave the

on and off times the same. The default times for each day will be 00:00 (midnight).

3.4 MENU SET B: TEMP SETTINGS

Pressing the Down arrow once followed by the Enter/Reset button will access the Temp Settings menu set. This

menu set has one option; to access the option, press the Enter/Reset button.

3.4.1 CH SETPOINT USER

This setting can be used to modify the boiler flow setpoint when operating in Central Heating mode. The setpoint

can be adjusted using the Up and Down buttons on the control panel. Once the desired setpoint is displayed, the

Enter/Reset button should be pressed to store the value.

12

3.5 MENU SET C: DATA LOGGING

Pressing the Down arrow 2 times followed by the Enter/Reset button will access the Data Logging menu set. This

menu set has four options that will display recorded data about the operation of the boiler. To access the options,

use the Up or Down buttons followed by the Enter/Reset button.

3.5.1 HRS. RUN CH

The Hrs. Run CH option shows the total time that the burner in the boiler has been operating for, under a central

heating demand, since the counter was last reset.

3.5.2 HRS. RUN DHW

The Hrs. Run DHW option shows the total time that the burner in the boiler has been operating for, under a

domestic hot water demand, since the counter was last reset.

3.5.3 IGNITION ATTEMPTS

The Ignition Attempts option will show the number of times the boiler has attempted to fire since the counter was

last reset.

3.5.4 LAST 10 ERRORS

The Last 10 Errors option will show the date, time and fault description for the last ten errors that caused the boiler

the stop. The Up or Down button should be used to scroll through the errors

3.6 MENU SET E: DHW SETTINGS

Pressing the Down arrow 3 times followed by the Enter/Reset button will access the DHW Settings menu set.

This menu set has one option; to access the option, press the Enter/Reset button.

3.6.1 DHW SETPOINT USER

This setting can be used to modify the setpoint of the storage tank. The setpoint can be adjusted using the Up

and Down buttons on the control panel. Once the desired setpoint is displayed, the Enter/Reset button should be

pressed to store the value.

The setpoint should be adjusted to ensure that the water is stored at 60°C and distributed at 50°C within 1 (one)

minute at all outlets. Care is needed to avoid much higher temperatures because of the risk of scalding. At 50°C

the risk of scalding is small for most people, but the risk increases rapidly with higher temperatures and for longer

exposure times. The risk to young children and to those with a sensory or mobility loss will be greater. Where a

significant scalding risk has been identified, the use of thermostatic mixing valves on baths and showers should be

considered to reduce temperature, these need to be placed as close to the point of use as possible.

3.7 MENU SET F: OUTDOOR RESET

Pressing the Down arrow 4 times followed by the Enter/Reset button will access the outdoor reset menu set. This

menu set has two options that control the outdoor reset function of the boiler. To access the options, use the Up

or Down buttons followed by the Enter/Reset button.

3.7.1 OUTDOOR AIR SHUTDOWN

When the outdoor air temperature rises above this setpoint, all central heating demands will be blocked (DHW

demands will remain active). The setpoint can be adjusted using the Up and Down buttons on the control panel.

Once the desired setpoint is displayed, the Enter/Reset button should be pressed to store the value. The default

value is 26.5°C

13

3.7.2 OUTDOOR AIR SHUTDOWN DIFFERENTIAL

The outdoor air shutdown differential is the number of degrees the outdoor air must drop in order to unblock heat

demands. If for example the outdoor air shutdown temperature is set at 26.5°C and the differential is set at 5°C,

heating demands will be blocked until the outdoor air temperature drops below 21.5°C

The differential can be adjusted using the Up and Down buttons on the control panel. Once the desired

differential is displayed, the Enter/Reset button should be pressed to store the value. The default value is 5°C

3.8 EXITING USER SETTINGS MODE

To exit the user-setting mode, the Menu/Exit button should be pressed whilst in the Main Menu screen.

Alternatively, if no button is pressed for 60 seconds, the boiler will revert to its normal operating screen. Once this

has occurred, the Enter/Reset button should be pressed to switch the unit on.

14

NOTES

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15

NOTES

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Lochinvar EcoKnight EKB235CE User manual

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Lochinvar EcoKnight EKB235CE User manual

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