Lochinvar EcoKnight EKB45CE 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

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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
2.3SEQUENCE 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
3.5.1HRS. 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

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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

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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 notbe 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)

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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.

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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.

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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/Exitbutton 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.

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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.

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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 resetmenu 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

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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.

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NOTES
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NOTES
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