Lochinvar EcoKnight EKW117 Service Manual
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Lochinvar EcoKnight EKW117 Service Manual

Lochinvar EcoKnight EKW117 Service Manual

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Models:
EKW117
EKW190
EKW237
EKW295
EcoKnight
Service Manual
Warning:
Read and fully understand this manual before attempting to work on this Water heater.
It can cause personal injury and damage to the Water heater when you do not read the
manual and/or do not obey the instructions.

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Summary of Contents for Lochinvar EcoKnight EKW117

  • Page 1 EcoKnight Service Manual Models: EKW117 EKW190 EKW237 EKW295 Warning: Read and fully understand this manual before attempting to work on this Water heater. It can cause personal injury and damage to the Water heater when you do not read the manual and/or do not obey the instructions.

  • Page 2: Document Identification

    Article Language Version Updated by EcoKnight Service manual English Launch OCUMENT IDENTIFICATION Page 1 of 50...
  • Page 3 IABILITY Maintenance engineer Lochinvar accepts no liability when the Appliance is not used correctly and requires the installation engineer to: • Read this manual carefully and obey the instructions. • Make sure that the entire Appliance installation complies with all applicable regulations.
  • Page 4 OMPLIANCE To safely produce low temperature hot water, the design and construction of the appliance is in accordance with: • UK and European Regulations 2016/426 on appliances burning gaseous fuels (GAR). • UK and European Standard for Gas–fired boilers (BS EN15502). •...

  • Page 5: About This Manual

    ABOUT THIS MANUAL COPE This manual gives information about safe and correct use of the Appliance and how installation, maintenance and service activities must be done correctly. You must obey the instructions in this manual. Caution Read this manual carefully before you start servicing the appliance. It can cause personal injury and damage to the unit when you do not read the manual and/or do not obey the instructions.

  • Page 6: Safety Guidelines

    • Do not re-enter the building until it is safe to do so. Lochinvar Limited is not liable for any damage caused by inaccurately following these instructions. Only original parts may be used when carrying out any repair or service work.

  • Page 7: Table Of Contents

    CONTENTS SAFETY GUIDELINES ........................5 WHAT TO DO IF YOU SMELL GAS ....................5 DISPLAY PANEL MENU ACCESS ....................7 GENERAL OPERATION ......................... 8 How the control module operates ..................8 Sequence of operation ......................8 Adjust set point temperature(s) ..................... 8 Installer password ........................

  • Page 8: Display Panel Menu Access

    The Navigation Section is located down the left side of the screen. There are five (5) sections located below the Lochinvar icon: Home, View, Setup, Information (About), and Settings. The Home Section is the screen shown in Figure 1. The View Section provides more detailed information including subsections for: History, Cascade, Graphing, and a complete list of current Sensor Values.

  • Page 9: General Operation

    GENERAL OPERATION The appliance uses an advanced stainless steel heat exchanger and an electronic control module that allows fully condensing operation. The fan pulls in gas and air and pushes products of combustion out of the appliance through the heat exchanger and flue system.
  • Page 10 ABLE EQUENCE OF PERATION Sequence of Operation Upon a call for heat, the control turns on the DHW pump. The control confirms that the low water cutoff / flow switch contacts are closed and energizes the (optional) louvers. The control confirms that the gas pressure switch, blocked drain switch, limits, louver proving switch (optional), and contacts close.
  • Page 11 ABLE PARAMETER TABLE This table lists SMART TOUCH control module parameters and where to access them. User Access Installer Access Display Modify Display Modify Menu Description Time and date Software version read only Temperature units (°C/°F) General DHW Night set back offset DHW Night set back On Times DHW Night set back Off Times Display timeout...
  • Page 12 Table 2 continued User Access Installer Access Display Modify Display Modify Menu Description BMS Tstat input BMS Tstat input ModBus ModBus T/O Cascade address Control Modes Cascade type Max cascade set point Min on/off time Min next on time Water heater size DHW pump delay Circulation pumps...

  • Page 13: Initial Setup

    OW TO SET CLOCK AND DATE Use the following procedure to set the clock: 1. Press the SETTINGS button under the Lochinvar Logo. (see figure 1) 2. Press the SET button across from the date and time. 3. Proceed to set the date and time.

  • Page 14: Viewable And Changeable Control Parameters

    IEWABLE AND CHANGEABLE CONTROL PARAMETERS Note: Before changing parameters, note the setting so that the unit can be returned to its original operating parameters & NIGHT SETBACK ON OFF TIMES This is the time in which the Night Setback Offset becomes active. There are 7 start times and 7 stop times each for the DHW night setback feature.

  • Page 15: Temperature Settings

    EMPERATURE ETTINGS IGURE TEMPERATURE SET POINTS DHW T OINT By installing a tank sensor, the SMART TOUCH control can perform the tank thermostat function. The SMART TOUCH control automatically detects the presence of this sensor and generates a DHW call for heat when the tank temperature drops below the tank set point differential (Tank Set point Differential parameter) and finishes the call for heat when the tank temperature reaches tank set point + offset.

  • Page 16: Anti-Cycling

    AXIMUM OINT This setting controls the maximum tank set point for the tank temperature. The installer can adjust this by accessing the Tank Maximum Set point parameter. The minimum setting is the minimum tank set point (Tank Minimum Set point parameter) and the maximum setting is 85°C.

  • Page 17: Control Modes

    IGURE ELAY CREEN ONTROL MODES BMS T HERMOSTAT NPUT When controlling the water heater through the 0 - 10V BMS input or through Modbus, the water heater can be enabled one of two ways. With the BMS Thermostat Input parameter set to ACTIVE, the water heater will be enabled by closing the tank thermostat input.
  • Page 18 ASCADE There are two (2) options for the way a Cascade divides the load between its heaters. The first is Lead/Lag, designated as L/L in the menu. This method is used when it is desired to have the least amount of total flow through the water heaters. This method will modulate the last two (2) water heaters.
  • Page 19 IGURE ASCADE ETUP IGURE ASCADE EADER ETUP Page 18 of 50...

  • Page 20: Circulation Pumps

    IGURE ASCADE EMBER ETUP CREEN IRCULATION UMPS DHW P ELAY The DHW pump delay parameter sets the length of time the DHW pump will run after a DHW demand has been satisfied. This parameter is adjustable by the installer by accessing the DHW Pump Delay parameter.

  • Page 21: Bms

    BMS T When programmed for BMS control through the 0 - 10V BMS input or through Modbus, the 0 - 10V signal can be interpreted as either a modulation command or a set point. When the BMS Type parameter is set to POWER, the 0 - 10V signal will control the modulation. When set to SETPOINT, the 0 - 10V signal will control the tank set point.

  • Page 22: Service Notification

    ERVICE OTIFICATION ERVICE OTIFICATION IN ONTHS When the water heater control determines that a scheduled service is due based on months of installation, the water heater display will alternate the standard water heater display text on the home screen with the message SERVICE DUE every 5 seconds. This parameter is adjustable by the installer by accessing the Service Notification in Months parameter.
  • Page 23 When the appliance control determines that a scheduled service is due based on the months of installation, the appliance display will turn yellow, and a new status screen will appear informing the installer that maintenance is required. AINTENANCE OTICE UNNING OURS When the appliance control determines that a scheduled service is due based on the hours of actual operation, the appliance display will turn yellow, and a new status screen will appear...

  • Page 24: Maintenance

    MAINTENANCE ERVICE AND AINTENANCE CHEDULES ABLE SERVICE SCHEDULE Service technician Daily Check water heater area Check flue piping Check air piping Check air and vent termination Check relief valves Check condensate drain piping Monthly Check vents Check delta T Check operation of flow switch Check any strainer fitted Check operation of all pumps Check water heater piping...
  • Page 25 Warning: Follow the service and maintenance procedures given throughout this manual and in literature shipped with the unit. Failure to perform the service and maintenance could result in damage to the unit, system and may result in serve personal injury, death, or substantial property damage.
  • Page 26 2. The condensate trap is equipped with a ball that acts as a seal against harmful flue gases escaping in the case there is no condensate in the trap. If this ball is not present, flue gases may be able to pass through the trap when there is no condensate present, resulting in an unsafe environment.
  • Page 27 HECK ALL PIPING FOR LEAKS Eliminate all system or appliance leaks. Continual fresh makeup water will reduce appliance life. Minerals can build up in sections, reducing heat transfer, overheating heat exchanger, and causing heat exchanger failure. Leaking water may also cause severe property damage.
  • Page 28 HECK ALL APPLIANCE WIRING 1. Inspect all unit wiring, making sure wires are in good condition and securely attached. HECK CONTROL SETTINGS 1. Set the smart touch control module display to parameter mode and check all settings. Adjust settings if necessary. 2.
  • Page 29 Failure to comply could result in severe personal injury. 13 R – H IGURE ASKET XCHANGER Rope Gasket Note: The rope gasket is intended for sealing combustion. If damaged DO NOT reuse, the rope gasket must be replaced. Contact Lochinvar for a replacement. Page 28 of 50...

  • Page 30: Waterside Maintenance

    If the water hardness is above 100ppm CaCO3 then the heat exchanger should be flushed with a descale fluid at least every 12 months. This may be more often depending on water quality and how hard the water heater is working, contact Lochinvar TSG for assistance. Procedure: 1. Turn off the water heater.

  • Page 31: Troubleshooting

    TROUBLESHOOTING Warning: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Always disconnect power to the unit before servicing. Failure to comply could result in severe personal injury, death, or property damage. EFORE TROUBLESHOOTING 1.
  • Page 32 ABLE ROUBLESHOOTING HART FAULT CAUSE CORRECTIVE ACTION • Check external line switch, fuse, or breaker. • Check position of ON/OFF switch. Turn switch to the ON position. • Check 230 vac through the No 230 VAC supplied to unit. ON/OFF switch. •...

  • Page 33: Checking Temperature Sensors

    HECKING TEMPERATURE SENSORS The unit 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 ohm meter to read the resistance of the sensor at a known temperature.
  • Page 34 – N ABLE ROUBLESHOOTING OISY YSTEM FAULT CAUSE CORRECTIVE ACTION Supply gas problem. • Refer to the Gas Connections section of the Natural gas pressures Installation and Operation Manual for detailed should be between information concerning the gas supply. 17.5 and 20mbar •...
  • Page 35 – F ABLE ROUBLESHOOTING AULT ESSAGES ISPLAY ON NTERFACE FAULT DESCRIPTION CORRECTIVE ACTION • Reset the pressure switches. • Measure the supply gas pressure to determine cause of failure. Natural gas pressures should be between 17.5 and 20mbar - Either the optional •...
  • Page 36 Table 7 Troubleshooting – Continued from previous page. FAULT DESCRIPTION CORRECTIVE ACTION • Check the wiring connections to switch. Wires should be connected to the common and normally closed terminals. • Air intake lengths exceed the maximum allowed lengths. Check flue guidance in ICM instructions.
  • Page 37 Table 7 Troubleshooting – Continued from previous page. FAULT DESCRIPTION CORRECTIVE ACTION • Check wiring harness connection at the gas valve and at the main control board. • Inspect spark electrode and associated wiring for damage and connection. Reference this manual for removal and cleaning procedures.
  • Page 38 Table 7 Troubleshooting – Continued from previous page. FAULT DESCRIPTION CORRECTIVE ACTION Flame Sequence (will require a • Check supply voltage for proper polarity. manual reset once • Check external wiring for voltage feedback. the condition has The flame detector circuit •...
  • Page 39 Table 7 Troubleshooting – Continued from previous page. FAULT DESCRIPTION CORRECTIVE ACTION Verify that the system is full of water and that all air has been properly purged from the system. • Verify that the water heater is piped correctly between water heater and buffer vessel.
  • Page 40 Table 7 Troubleshooting – Continued from previous page. FAULT DESCRIPTION CORRECTIVE ACTION Sensor Shorted Either the inlet Check the sensors and their associated wiring. (Will require a manual water or outlet Repair or replace the sensor or wiring if reset once the condition has water damaged.
  • Page 41 Table 7 Troubleshooting – Continued from previous page. FAULT DESCRIPTION CORRECTIVE ACTION • Verify that the system is full of water and that all air has been properly purged from the system. • Verify that the water heater is piped properly between the water heater and buffer vessel.
  • Page 42 Table 7 Troubleshooting – Continued from previous page. FAULT DESCRIPTION CORRECTIVE ACTION The main control board Watch Dog Error • Replace the main control board. has detected an internal fault. The main control board Write EEProm • Replace the main control board. has detected an internal fault.
  • Page 43 HECK FLAME AND COMBUSTION 1. Turn the main power off to the unit by placing the “On/Off switch in the off position. 2. Remove the flue temperature sensor from the flue pipe connection. Combustion measurements will made at this point. 3.
  • Page 44 AS VALVE ADJUSTMENT PROCEDURE 1. For EKW117: Remove the front panel from the unit. For EKW190, 235, 295: Remove the top access cover from the unit. 2. For EKW190, 235, 295: Remove the cover on top of the gas valve. 3.

  • Page 45: Appendix 1 Control Inputs

    APPENDIX 1 CONTROL INPUTS Page 44 of 50...

  • Page 46: Appendix 2 Control Outputs

    APPENDIX 2 CONTROL OUTPUTS Page 45 of 50...

  • Page 47: Appendix 3 Spare Parts Finder

    APPENDIX 3 SPARE PARTS FINDER Item No Description of item Item Comments EKW117CE EKW190CE EKW235CE EKW295CE Heat Exchanger LL100330273 LL100330275 LL100330276 LL100330277 Low Voltage Connection Board Prior Serial #2148 LL100208459 Low Voltage Connection Board Beg Serial #2148 LL100351933 Main Control Board LL100330278 LL100334033 LL100334034 LL100334035 Display Assembly LL100330279...
  • Page 48 Gas valve and combustion train Casings and externally sited items Page 47 of 50...
  • Page 49 Control boards Heat exchanger and burner Page 48 of 50...
  • Page 50 Page 49 of 50...
  • Page 51 Page 50 of 50...

This manual is also suitable for:

Ecoknight ekw190Ecoknight ekw237Ecoknight ekw295

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