Econcept 101 Manual
Contents
1. 3 4 Electrical connections Connection to the electrical grid A The unit s electrical safety is only guaranteed when correctly connected to an efficient earthing system executed according to current safety standards Have the efficiency and suitability of the earthing system checked by professionally qualified personnel The manufacturer is not responsible for any damage caused by failure to earth the system Also make sure that the electrical system is adequate for the maximum power absorbed by the unit as specified on the boiler dataplate The boiler is prewired and provided with a Y cable and plug for connection to the elec tricity line The connections to the grid must be made with a permanent connection and equipped with a bipolar switch whose contacts have a minimum opening of at least 3 mm interposing fuses of max 3A between the boiler and the line It is important to re spect the polarities LINE brown wire NEUTRAL blue wire EARTH yellow green wire in making connections to the electrical line During installation or when changing the power cable the earth wire must be left 2 cm longer than the others The user must never change the unit s power cable If the cable gets damaged switch off the unit and have it changed solely by professionally qualified person nel If changing the electric power cable use solely HAR H05 VV F 3x0 75 mm2 cable with a max2. FERROLI S p A Via Ritonda 78 37047 San Bonifacio VR ycim EC 2009 142 92 42 korniB 73 23 93 68 89 336 93 68 D Feli Ferroli FERROLI S p A Via Ritonda 78 a 37047 San Bonifacio Verona ITALY www ferroli it
3. 193 IN 193 154 193 16 154 252 252 252 Y fig 44 Water circuit 51 511 fig 45 Water circuit ECONCEPT 101 101i 10 System delivery 11 System return 32 Heating circulating pump 154 Condensate outlet pipe 161 Condensing heat exchanger 186 Return sensor 193 Trap 252 3 way drain and shutoff cock 253 Shutoff cock 278 Double sensor Safety Heating 58 cod 35408572 11 2010 Rev 00 ECONCEPT 51 51i 101 101i Ferroli 5 4 Technical data table 5 6 Wiring diagram The column on the right gives the abbreviation used on the dataplate Important Before connectingthe room thermostat or the remote timercontrol remove the jumper on the terminal block A Only model ECONCEPT 101 101i 1 16 Fan 51 511 101 Data Unit 401i 32 Heating circulating pump Max heating capacity kW 49 8 99 6 0 P 7 sensor nor supplied Min heating capacity kw 11 2 11 2 0 72 Room thermostat not supplied Max Heat Output in heating 80 60 KW 48 8 97 6 P 72b Second room thermostat not supplied Min Heat Output in heating 80 60 C kW 10 110 A e eeina d Min Heat Output in heating 50 30 C kW 53 0 106 0 95 Diverter valve not supplied Min Heat Output in heating 50 30 C KW 120 12 0 Heating phas
4. Uygunluk beyani imalatgi FERROLI S p A Adres Via Ritonda 78 a 37047 San Bonifacio VR bu cihazin asagida yer alan AET EEC y nergelerine uygunluk iginde oldugunu beyan etmektedir 2009 142 Gazla calistirilan niteler Y netmelik 92 42 Randiman Verimlilik Y netmeligi Y nerge 73 23 D s k Voltaj 93 68 nolu direktifle degisiklige ugratildi 89 336 Elektromanyetik Uygunluk Y netmeligi 93 68 ile degisiklik yapilmistir Baskan ve yasal temsilci Dep Dante Feyoli Declaration of conformity Manufacturer FERROLI S p A Address Via Ritonda 78 a 37047 San Bonifacio VR Italy declares that this unit complies with the following EU directives Gas Appliance Directive 2009 142 Efficiency Directive 92 42 Low Voltage Directive 73 23 amended by 93 68 Electromagnetic Compatibility Directive 89 336 amended by 93 68 President and Legal Representative Cav del Lavoro ante Ferrpli EGE D claration de conformit Le constructeur FERROLI S p A C Adresse Via Ritonda 78 a 37047 San Bonifacio VR d clare que cet appareil est conforme aux directives CEE ci dessous Directives appareils gaz 2009 142 Directive rendements 92 42 Directive basse tension 73 23 modifi e 93 68 Directive Compatibilit Electromagn tique 89 336 modifi e 93 68 Pr sident et fond de pouvoirs Cav du travail Dante Feryoli Li Declaratie de conformitate Prod
5. Ferroli ECONCEPI 51 101 ECONCEPT 511 1011 ISTRUZIONE PER L USO L INSTALLAZIONE E LA MANUTENZIONE INSTRUCCIONES DE USO INSTALACI N Y MANTENIMIENTO KULLANMA KURULUM VE BAKIM TALIMATLAR INSTRUCTIONS FOR USE INSTALLATION AND MAINTENANCE INSTRUCTIONS D UTILISATION D INSTALLATION ET D ENTRETIEN INSTRUCTIUNI DE UTILIZARE INSTALARE SI INTRETINERE 3 TA cod 35405572 11 2010 Rev 00 51 51i 101 101i EN 1 GENERAL INSTRUCTIONS Carefully read the instructions contained in this instruction booklet After boiler installation inform the user regarding its operation and give him this manual which 15 an integral and essential part of the product and must be kept with care for future reference Installation and maintenance must be carried out by professionally qualified personnel according to current regulations and the manufacturer s instructions Do not carry out any operation on the sealed control parts Incorrect installation or inadequate maintenance can result in damage or injury The Manufacturer declines any liability for damage due to errors in installation and use or failure to follow the instructions Before carrying out any cleaning or maintenance operation disconnect the unit from the power supply
6. 1 to adjust the tempera ture from a min of 20 C to a Max or9U C fig 8 DHW temperature adjustment with optional hot water tank installed Use the DHW buttons gt details 1 and 2 fig 1 to adjust the temperature from a min of 10 C to a M x of 05 C ECONCEPT 51 51i 101 101i Room temperature adjustment with optional room thermostat Using the room thermostat set the temperature required in the rooms Room temperature adjustment with optional remote timer control Using the remote timer control set the temperature desired in the rooms The boiler unit will set the system water according to the required room temperature For information on the remote timer control please refer to its user s manual Sliding temperature When the optional external probe is installed the corresponding symbol detailfig 122 is activated on the control panel display detail 5 fig 1 The boiler control system op erates with Sliding Temperature In this mode the heating system temperature is ad justed according to the outside weather conditions to ensure high comfort and energy saving throughout the year In particular as the outside temperature increases the sys tem delivery temperature is decreased according to a specific compensation curve details 3 and 4 fig 1 becomes the maximum system delivery temper ature It is advisable to set a maximum value to allow system adjustment throughout its useful ope
7. Gas inlet System delivery System return Condensate drain Blind flanges Connection side Flanges with joining section Plumbing connection using two or more generators with hydraulic separator 1 2 OP os E d EE Ol U WU WU VU up vu 5 7 T 6 7 4 fig 17 Gas inlet System delivery System return Condensate drain Blind flanges Connection side Flanges with joining section Seals ONOoahWN Plumbing connection using one or more generators with direct pump EI it ATTE e a 294 ed CH 4 em y EL I 7 Y 7 9 8 fig 18 Gas inlet System delivery System return Condensate drain Blind flanges Connection side Flanges with joining section Seals Delivery return connection CONDURWN Water circuit examples Key of examples ISPESL safety devices D Hydraulic separator 42 DHW temperature sensor not supplied 72 Room thermostat not supplied 72b Room thermostat not supplied 95 3 way valve with spring return at rest on DHW side not supplied 130 Hot water tank circulating pump not supplied 138 External probe not supplied 139 Remote control not supplied 298 Cascade temperature sensor not supplied 306 Heating system circulating pump not supplied 307 Heating system second circulating pump not supplied SM Delivery probe supplie
8. Rev 00 ECONCEPT 51 51i 101 101i If the Remote Timer Control optional is connected to the boiler the above ad justments are managed according to that given in table 1 Table 1 Heating temperature adjustment Adjustment can be made from the Remote Timer Control menu and the boiler control panel DHW temperature adjustment with Adjustment can be made from the Remote Timer Control menu and the boiler control optional hot water tank installed panel Summer Winter Switchover Eco Comfort selection with optional hot water tank installed Summer mode has priority over a possible Remote Timer Control heating demand On disabling DHW from the Remote Timer Control menu the boiler selects the Econ mode In this condition the button fig 1detail 7 on the boiler panel is disabled On enabling DHW from the Remote Timer Control menu the boiler selects the Com fort mode In this condition it is possible select one of the two modes with the button detail 7 fig 1 Both the Remote Timer Control and the boiler card manage Sliding Temperature adjustment of the two the Sliding Temperature of the boiler card has priority Sliding Temperature System water pressure adjustment The filling pressure with the system cold must be approx 1 0 bar If the system pressure falls to values below minimum the boiler card will activate fault F37 fig 14 Flashing of the arrows details 18 and 24 fig 1
9. 1KWMA84A on the 280 pipes leaving the unit and make it adhere to the upper wall of the cabinet Before proceeding with installation make sure the maximum permissible length has not been exceeded by means of a simple calculation 1 Establish the layout of the system of split flues including accessories and outlet ter minals for each of the two burner exchanger bodies 2 Consult the table 3 and identify the losses meq equivalent metres of every com ponent according to the installation position 3 Checkthat the sum total of losses is less than or equal to the maximum permissible Ferroli Connection with manifolds To connect one or more modules in bank to a single flue itis advisable to use the special manifolds optionals indicated in the table The choice of diameter must be made ac cording to the total power of the bank of units respecting that given in the table Use a starting kit for each bank and a suitable number of extension kits The starting kits have a special accessory inside them for connection also to modules 51 511 90 bends and manifold extensions are also available for the flue connection length in table 2 Manifold extension apo pend Bank heating capacity Manifold di
10. 7 6 0 500 1 000 1 500 2 000 2 500 l h fig 46 Boiler pressure losses 1 2 3 Circulating pump speed 59 cod 35408572 11 2010 Rev 00 DBM12KC v1 44 ECONCEPT 51 511 101 101i 82 MI DBM12KC 995999999909 56 130 307 4 56 7 8 9 Ode x OO ROROROROROROTRO ROO O 3 4 AT 48 49 20 21 22 23 24 25 26 27 28 29 30 DSP12C fig 47 Wiring diagram 60 cod 35408572 11 2010 Rev 00 Dichiarazione conformita ll costruttore FERROLI S p A Indirizzo Via Ritonda 78 a 37047 San Bonifacio VR dichiara che questo apparecchio conforme alle seguenti direttive CEE Direttiva Apparecchi a Gas 2009 142 Direttiva Rendimenti 92 42 Direttiva Bassa Tensione 73 23 modificata dalla 93 68 Direttiva Compatibilit Elettromagnetica 89 336 modificata dalla 93 68 Presidente e Legale rappresentante Cav del Lavoro Dante Feyoli Declaraci n de conformidad El fabricante FERROLI S p A Direcci n Via Ritonda 78 a 37047 San Bonifacio Verona declara que este equipo satisface las siguientes directivas CEE Directiva de Aparatos de Gas 2009 142 Directiva de Rendimientos 92 42 Directiva de Baja Tensi n 73 23 modificada por la 93 68 Directiva de Compatibilidad Electromagn tica 89 336 modificada por la 93 68 Presidente y representante legal Caballero del Trabajo Dante Fegoli
11. Change parameter 02 of the System Type Menu to 1 Change parameter P 09 of the System Type Menu to 1 72 139 o fig 22 Two mixed heating circuits and one direct heating circuit Check Change parameter 02 of the Transparent Parameters Menu to 1 Change parameter 02 of the System Type Menu to 1 Change parameter P 09 of the System Type Menu to 1 For the electrical connection and the zone system settings refer to the FZ4 zone reg ulator handbook J O Zona2 Zona3 Zona1 298 Ferroli Two mixed heating circuits one direct heating circuit and one DHW circuit with pump Check Change parameter 02 of the Transparent Parameters Menu to 2 Change parameter P 02 of the System Type Menu to 1 Change parameter P 09 of the System Type Menu to 1 For the electrical connection and the zone system settings refer to the FZ4 zone reg ulator handbook
12. Turning the boiler off When the boiler is turned off the PCB is still powered Domestic hot water with optional hot water tank installed and heating operation are dis abled The antifreeze system remains activated To relight the boiler press the button detail 7 fig 1 again for 5 seconds The boiler will be immediately ready to operate whenever domestic hot water is drawn with optional hot water tank installed or in case of a room thermostat demand To completely disconnect the power to the unit press the button detail 14 fig 1 The antifreeze system does not work when the power and or gas to the unit are turned off To avoid damage caused by freezing during long idle periods in win ter itis advisable to drain all water from the boiler DHW circuit and system or drain just the DHW circuit and add a suitable antifreeze to the heating system complying with that prescribed in sec 3 3 2 4 Adjustments Summer Winter Switchover Press the button detail 6 fig 1 1 second fig 7 The display activates the Summer symbol detail 10 fig 1 The heating function is deac tivated whereas the possible production of domestic hot water with optional external hot water tank remains activated The antifreeze system remains activated To deactivate Summer mode press the button EEI detail 6 fig 1 again for 1 sec ond Heating temperature adjustment Use the heating buttons details 3 and 4 fig
13. exit the card System Type Menu One direct heating circuit Check Change parameter 02 of the Transparent Parameters Menu to 1 Change parameter P 02 of the System Type Menu to 1 Change parameter P 09 of the System Type Menu to 1 138 11727139 o fig 19 One direct heating circuit and one DHW circuit with pump Check Change parameter 02 of the Transparent Parameters Menu to 2 Change parameter 02 of the System Type Menu to 1 Change parameter 09 of the System Type Menu to 1 727139 fig 20 NZN cod 35408572 11 2010 Rev 00 ECONCEPT 51 51i 101 101i One direct heating circuit and one DHW circuit with diverter valve Check Change parameter 02 of the Transparent Parameters Menu to 3 Change parameter P 02 of the System Type Menu to 1 Change parameter P 09 of the System Type Menu to 1 Change parameter P 11 of the System Type Menu to 1 138 i 72 139 fig 21 Two direct heating circuits Check Change parameter 02 of the Transparent Parameters Menu to 1 Change parameter 01 of the System Type Menu to 4
14. heating standby time the message d Activation of the arrows details 18 and 24 fig 1 indicates which boiler shell is on Exclude hot water storage tank economy Hot water tank temperature maintaining heating can be excluded by the user If exclud ed domestic hot water will not be delivered The hot water tank can be deactivated by the user ECO mode by pressing the eco comfort button detail 7 fig 1 In ECO mode the display activates the symbol detail 12 fig 1 To activate the COMFORT mode press the eco comfort button detail 7 fig 1 again 2 3 Lighting and turning off Boiler lighting Press the On Off button detail 14 fig 1 E fig 4 Boiler lighting Forthe following 120 seconds the display will show which identifies the heating System air venting cycle During the first 10 seconds the display will also show the software version of the cards A 7 Display card software version B Top boiler shell control unit software version C Bottom boiler shell control unit software version model ECONCEPT 101 101ionly Open the gas cock ahead of the boiler When the message FH disappears the boiler is ready to operate automatically in case of a room thermostat demand cod 35408572 11 2010 Rev 00 47 Ferroli Turning the boiler off Press the button detail 7 fig 1 for 5 seconds reset comfort fig 5
15. sure the water is circulating properly between the boiler and the systems Make sure the gas modulates correctly in the heating and domestic hot water production phases Check proper boiler lighting by doing several tests turning it on and off with the room thermostat or remote control Using a combustion analyser connected to the boiler fume outlet check that the CO content in the fumes with the boiler operating at max and min output corre sponds to that given in the technical data table for the corresponding type of gas Make sure the fuel consumption indicated on the meter matches that given in the technical data table on sec 5 4 Checkthe correct programming of the parameters and carry out any necessary cus tomization compensation curve power temperatures etc 4 3 Maintenance Periodical check To keep the unit working properly over time it is necessary to have qualified personnel make an annual check that includes the following tests The control and safety devices gas valve flow meter thermostats etc must func tion correctly The fume extraction circuit must be fully efficient The airtight chamber must be sealed The air fume end piece and ducts must be free of obstructions and leaks The condensate evacuation system must be efficient with no leakage or obstruc tions The burner and exchanger must be clean and free of scale When cleaning do not use chemical products or wire
16. together with the error code indicates which boiler shell is in fault status Once the system pressure is restored the boiler will activate the 120 second air venting cycle indicated on the display by FH 3 INSTALLATION 3 1 General Instructions THE BOILER MUST ONLY BE INSTALLED BY QUALIFIED PERSONNEL IN COMPLI ANCE WITH ALL THE INSTRUCTIONS GIVEN IN THIS TECHNICAL MANUAL THE PROVISIONS OF CURRENT LAW THE NATIONAL AND LOCAL REGULATIONS AND THE RULES OF PROPER WORKMANSHIP ECONCEPT 51 51i 101 101i is a high efficiency heat generator arranged to operate alone or in cascade bank When two or more generators ECONCEPT 51 51i 101 101i are installed in cascade with the original kits FERROLI respecting the prescriptions of this manual they can be considered as a single heat generator of total power equal to the sum of the powers of all the units connected in cascade All the requirements of the current standards and regulations applicable to this equiva lent generator with total heating capacity must be met In particular the place of instal lation safety devices and fume exhaust system must be adequate for the total heating capacity of the bank of units In fact each ECONCEPT 51 51i 101 101i is a complete and independent heat gener ator equipped with its own safety devices In case of overtemperature a lack of water or no circulation in the unit the protection devices cause the unit to switch off or shut down prevent
17. ulations for the complete modular generator They must be installed on the hot water cir cuit delivery piping immediately downstream of the last module within a distance of 0 5 m with no shut off devices in between A Safety Device and Circuit Breaker module equipped with internal hydraulic circuit breaker and safety units with ISPESL certification is available by request Refer to the price list or contact our sales network The unit is not supplied with an expansion tank its connection must therefore be made by the Installer A Water system characteristics A filter must also be installed on the system return piping to prevent impurities or sludge from the system clogging and damaging the heat generators The filter must necessarily be installed when replacing generators in existing systems The manufacturer declines any liability for damage caused to the gen erator by failure to install or inadequate installation of this filter In the presence of water harder than 25 Fr itis advisable to use suitably treated water in order to avoid possible scaling in the boiler caused by hard water or corrosion pro duced by aggressive water Due to its low thermal conductivity scaling even just a few mm thick causes significant overheating of the generator walls with consequent serious problems Water treatment is indispensable in case of very large systems containing large amounts of water or with frequent introduction of replenishing wa
18. ameter Starting kit Extension kit Male female for manifold Table 2 Max length separate ducts opo moni 9 P Up to 150 kW 125 mm 041008X0 041020X0 041017X0 041014X0 Separate ducts 150 300 kW 160 mm 041009X0 041011X0 041018X0 041015X0 For each single Exchanger Burner Body 300 500 kW 200 mm 041010X0 041012X0 041019X0 041016X0 Max permissible length 20 meq Installation examples 041008X0 Table 3 Accessories El Losses in m ma Lo Fume exhaust N Vertical Horizontal 041017X0 041014X0 080 PIPE 1 m M F 1KWMA83W 1 6 20 BEND 45 1KWMA65W 1 8 5 90 1KWMA01W 2 0 PIPE SECTION with test point 1KWMA70W 0 3 TERMINAL fumes wall with antiwind 1KWMA86A 5 0 FLUE Split air fumes 80 80 1KWMA84U 5 0 Direct connection of terminals Y 80 code 041013X0 Each single module can be connected directly to the terminal kits 041013X0 as given in even with connection in bank fig 29 d Each kit comprises a 280 terminal with grille ref 3 a seal ref 1 and a centering ring ref 2 For models ECONCEPT 101 101i use 2 kits per module and 1 kit for models ECONCEPT 51 51i fig 31 Installation of one module 041016X0 041010X0 041012X0 041012X0 041012X0 041012X0 4 4 4 4 LI I Lh L 1 mm L I I 1 12 3 1 ijy L Ju E 1 5 ars arto i ars 20 25 fig 29 Before installing the flues open the cabinet and fill the trap with approx 0 5 of water through the flue connections s
19. and air inlet and terminals Trap blocked Check the trap and clean it if necessary Flue partially obstructed Check the efficiency of the flue fume or insufficient extraction ducts and outlet terminal F07 High fume temperature Check the correct positioning and opera Fume sensor position tion of the fume sensor Sensor damaged F10 Delivery sensor 1 fault Wiring shorted Check the wiring or replace the sensor Wiring disconnected Sensor damaged F11 Return sensor fault Wiring shorted Check the wiring or replace the sensor Wiring disconnected Sensor damaged Lu F12 DHW sensor fault Wiring shorted Check the wiring or replace the sensor P Wiring disconnected Sensor damaged F13 Fume sensor fault Wiring shorted Check the wiring or replace the sensor Wiring disconnected Sensor damaged F14 Delivery sensor 2 fault Wiring shorted Check the wiring or replace the sensor Wiring disconnected fig 41 Dimensions and connections No 230V power supply Check the wiring of the 3 pin connector A Model ECONCEPT 51 51i 15 Fan fault Tachometric signal inter Check the wiring of the 5 pin connector B Model ECONCEPT 101 101i rupted 1 Gas inlet Fan damaged Check the fan 2 Heating system delivery SUV val 4 3 Heating system return F34 a Electric mains trouble Check the electrical system F35 Faulty mains frequency Electric mains trouble Check the electrical system Pressure too low Fill the system F37 Incorrect system water Water pressure switch pressure da
20. brushes The electrode must be free of scale and properly positioned The gas and water systems must be airtight The water pressure in the cold water system must be about 1 bar otherwise bring it to that value Thecirculation pump must not be blocked The expansion tank must be filled The gas flow and pressure must correspond to that given in the respective tables The boiler casing panel and aesthetic parts can be cleaned with a soft damp cloth possibly soaked in soapy water Do not use any abrasive detergents and solvents cod 35408572 11 2010 Rev 00 55 Ferroli ECONCEPT 51 511 101 101i 4 4 Troubleshootin Fault code Fault Possible cause Cure Diagnostics iri 9 Spy Probe damaged or wiring Check the wiring or replace the sensor The boiler is equipped with an advanced self diagnosis system In case of a boiler fault shorted the display will flash together with the fault symbol detail 20 fig 1 indicating the fault F39 External probe fault Probe disconnected after f ay igh RS Reconnect the external probe or disable code Flashing of the arrows details 18 and 24 fig 1 togethe
21. connections terminals 4 to 24 on module no 1 On the remaining modules only connect the power supply and possible contacts for burner lit 300 fault contact 301 and remote reset input 302 Switch on the power to the entire cascade After the FH procedure check correct operation of the cascade Module 1 arrow symbol top left of the display Module 2 arrow symbol at bottom right of the display Module 3 arrow symbol at bottom right of the display Module 4 arrow symbol at top right of the display If this does not occur disconnect the power and check the wiring in fig 27 Settings adjustments must be made on all the modules Possible faults If the electrical connection of a module is disconnected for any reason module 1 will ac tivate fault F70 If the electrical connection of a module is disconnected for any reason the next module will activate fault F71 ECONCEPT 51 511 101 101i 3 5 Flue connection Important The unit is a B23 type with combustion air drawn from the installation room and fume ex haust by means of a fan operation with flue pressurised and must be connected to one ofthe discharge systems indicated below Before proceeding with installation check and carefully comply with the local regulations and provisions Also comply with the provi sions concerning the positioning of wall and or roof terminals and minimum distances from windows walls ventilation openings
22. d with kit FZ4 TS Safety thermostat not supplied PZ Zone pump not supplied FZ4 Zone regulator Parameters Each system requires a different parametrisation Follow the procedure for accessing the two menus given below for the parameters to be modified refer to the tables given next to the plumbing diagrams ECONCEPT 51 511 101 101i Service Menu Press the Reset button for 10 seconds to access the card Service Menu Press the Heating buttons to select tS In Hi or rE tS means Transparent Pa rameters Menu In Information Menu Hi History Menu and History Menu Reset Select tS and press the Reset button The card has 29 transparent parameters also modifiable from Remote Control Service Menu Press the Heating buttons to scroll the list of parameters in increasing or decreasing or der Press the DHW buttons to modify the value of a parameter the change will be au tomatically saved Press the Reset button to return to the Service Menu Press the Reset button for 10 sec onds to exit the card Service Menu System Type Menu Press the Summer Winter button for 10 seconds to access the card System Type Menu The card has 21 transparent parameters Press the Heating buttons to scroll the list of parameters in increasing or decreasing or der Press the DHW buttons to modify the value of a parameter the change will be au tomatically saved Press the Summer Winter button for 10 seconds to
23. e Gas supply pressure G20 mbar 20 20 B DHW phase Max gas delivery G20 mh 5 27 10 54 C Neutral Min gas delivery G20 m h 1 19 1 19 NOTE For valves with 2 wires and spring return use the connections B and C Gas supply pressure G31 mbar 37 37 98 Switch 5 3 114 Water pressure switch Max gas delivery 631 kg h 39 78 130 DHW circulating pump not supplied Min gas delivery G31 kg h 0 88 0 88 138 External probe not supplied 139 Remote timer control not supplied 186 Return sensor 191 Fume temperature sensor Efficiency class Directive 92 42 EEC A 278 Double sensor Safety Heating 298 Cascade temperature sensor not supplied NOx emission class 5 5 NOx 299 Input 0 10 Vdc CO max 620 9 9 300 Burner lit contact voltage free contact 301 Fault contact voltage free contact 0 CO min 620 85 85 302 Remote reset input 230 Volt CO max G31 10 5 10 5 306 Heating system circulating pump not supplied 2 307 Heating system second circulating pump not supplied CO min G31 9 5 9 5 Max working pressure in heating bar 6 6 PMS Min working pressure in heating bar 0 8 0 8 Max heating temperature C 95 95 tmax Heating water content litres 10 12 8 Protection rating IP X5D X5D Power supply voltage V Hz 230V 50Hz 230V 50Hz Electrical absorption 190 380 Empty weight kg 124 150 Type of unit PIN CE 0461850878 5 5 Diagrams Circulating pump head pressure H mH O
24. e see sec 4 1 4 2 Start up Checks to be made at first lighting and after all maintenance operations that involved disconnection from the systems or an operation on safety devices or parts of the boiler Before lighting the boiler e Open any on off valves between the boiler and the systems Check the tightness of the gas system proceeding with caution and using a soap and water solution to detect any leaks in connections Check correct prefilling of the expansion tank ref sec 5 4 Fill the water system and make sure all air contained in the boiler and the system has been vented by opening the air vent valve on the boiler and any vent valves on the system Fillthe condensate trap and check correct connection of the condensate elimination System Make sure there are no water leaks in the system DHW circuits connections or boil er e Check correct connection of the electrical system and efficiency of the earthing sys tem Make sure the gas pressure value for heating is that required Make sure there are no flammable liquids or materials in the immediate vicinity of the boiler Ferroli Checks during operation Turn the unit on as described in sec 2 3 Make sure the fuel circuit and water systems are tight Check the efficiency of the flue and air fume ducts while the boiler is working Check the correct tightness and functionality of the condensate elimination system and trap Make
25. ee fig 30 A and B for the model and ECONCEPT 101 101ionly A the model ECONCEPT 51 51i fig 30 Filling the trap For outside installations make the seal 1 adhere perfectly to the top part of the cabinet to prevent possible infiltration of rain and atmospheric agents A fig 32 Installation of 5 modules For installation fig 33 A Insert the diameter 100 M F pipe sections with fume inspection 1 and the re spective seals 2 from the outside of the modules for each flue connection Respect the distance given in the box of fig 33 This distance must be in creased by 5 mm with each additional module Open the cabinets and install the anti backflow valve 3 on eachflue cod 35408572 11 2010 Rev 00 tion D 80mm fig 34 Make sure to correctly fit the seals Lengthen the diameter 100mm extensible part of each valve until it rests on the inner part of the casing Fix with the screw 4 Pour 1 2 litre of water on each flue in order to fill the respective traps and anti backflow valves Repeat the above steps for all the flue connections of the modules fig 35 Fit the manifold support flanges 5 using the special holes provided on the top of the modules The starting bracket on the first module must re spect the distance of 45
26. etc Manifold ducts and flue must be suitably sized designed and made in compliance with current regulations These must be made of suitable materials i e resistant to heat and corrosion smooth on the inside and hermetic In particular joints must be condensate tight Also provide for suitable condensate drain points connected to a trap to prevent the condensate formed in the flues from running into the generators The unit is equipped with two separate 280 flue connections for the two burner exchanger units fig 28 located inside the cabinet The combustion circuits of the two units are completely independent When joining the two fume outlets to a single flue or manifold in case of a single mod ule or connection in cascade it is necessary to install a fume anti backflow valve on each outlet to prevent operation anomalies or to creation of hazard ous conditions Make sure to use the optional kits FERROLI provided with spe cial anti backflow valves for installing inside the cabinets in a position protected against the atmospheric agents Before carrying out the flue connection make sure to fill the condensate tank as indicated incap 3 6 700 1650 fig 28 v IEN cod 35408572 11 2010 Rev 00 ECONCEPT 51 51i 101 101i Connection with separate pipes Separate 080 ducts can be connected directly to the unit Insert the seal
27. imum outside diameter of 8 mm Room thermostat optional CAUTION The room thermostat must have clean contacts CONNECTING 230 V TO THE TERMINALS OF THE ROOM THERMOSTAT WILL IRREPA RABLY DAMAGE THE ELECTRONIC CARD When connecting a remote timer control or a timer switch do not take the pow er supply for these devices from their cut out contacts Their power supply must be taken with a direct connection from the mains or with batteries depending on the kind of device External probe optional Connect the probe to its respective terminals The maximum permissible length for the boiler external probe connection electrical cable is 50 m A normal 2 wire cable can be used The external probe should preferably be installed on the North North West wall or that facing the largest area of living room The probe must never be exposed to the early morning sun or insofar as possible direct sunlight protect it if necessary In any case the probe must not be installed near windows doors ventilation openings flues or heat Sources that could affect the reading E X X X D D x fig 25 External probe positioning not recommended cod 35408572 11 2010 Rev 00 51 Ferroli Accessing the electrical terminal block The electrical terminal block is located inside a sealed box at the bottom left of
28. in the kit Connect a 240 pipe to the condensate drain pipe for removing the condensate pro duced during operation see fig 37 Fitthe blind flanges contained in the kit on the opposite side of the module inserting the special seals To connect several modules in cascade fig 17 Connectthe first module to the system and gas pipes as described above but with out fitting the blind flanges on the opposite side to that of the connection Place the second module on this side making sure to align the connection flanges and the condensate drain pipe Insert the seals contained in the kit between the flanges of the two modules e Fitthe bolts contained in the kit on the flanges from inside the first module making them come out of the flanges inside the second module Partially tighten the nuts on the bolts from inside the second module Before tightening the nuts make sure all the seals are correctly positioned and join the condensate drain pipes of the two modules see fig 38 Tighten the nuts and repeat the connection operations for the following modules max 5 If using a water trap Atthe end fitthe blind flanges on the last module inserting the special seals fig 16 and fig 17 If using a direct pump Connect the delivery to the return on the last module see fig 18 cod 35408572 11 2010 Rev 00 49 Ferroli Plumbing connection using one generator with water trap
29. ing it from working The installation instructions given in the following paragraphs concern both single units and connection in cascade 3 2 Place of installation The generator can be installed directly outside or in a suitable room with ventilation open ings to the outside as prescribed by the current regulations If there are several burners or extraction units that can work together in the same room the ventilation openings must be sized for simultaneous operation of all the units The place of installation must be free of flammable objects or materials corrosive gases volatile substances or dusts For positioning leave enough space around the modules for normal maintenance oper ations Make sure the front door opens without hindrance tom and top part of the unit Make sure these air passages are not obstructed A BES cw GT l The air necessary for combustion enters through special openings in the bot fig 15 Air inlet Ferroli 3 3 Gas and water connections Plumbing connections Make the relevant connections according to the instructions given below Make the gen erator connection in such a way that its internal pipes are free of stress For proper op eration and long life of the generator the plumbing system must be of suitable size and complete with all the accessories that guarantee regular operation and running In particular provide for all the protection and safety devices prescribed by current reg
30. maged or not con Check the sensor nected 56 cod 35408572 11 2010 Rev 00 ECONCEPT 51 511 101 101i 5 2 General view and main components PA 179 e 36 32 253 fig 42 General view ECONCEPT 51 511 Gas inlet System delivery System return Fan Combustion chamber Burner Heating circulating pump Automatic air vent Gas valve Detection electrode Water pressure switch Condensate outlet pipe Condensing heat exchanger Non return valve Return sensor Ignition electrode Trap Condensate tray 3 way drain and shutoff cock Shutoff cock Double sensor Safety Heating Cascade control unit and support bracket optional TEN 154 L pes gt Ferroli 16 44 A HOJ 278 81 161 al L 19 196 LIE E ES 193 22 16 278 V 44 81 161 196 19 186 193 7 Ns 114 179 2 b 2524 ak a 1 253 fig 43 General view ECONCEPT 101 101i cod 3540S572 11 2010 Rev 00 57 Ferroli ECONCEPT 51 51i 101 101i 5 3 Water circuit 278 e 278 186
31. mm see box G fig 35 This distance must be increased by 5 at a time in the following modules in order to obtain the fume manifold angle as indicated in fig 32 Fit the condensate trap 6 support bracket on the flange of the first module Insert the 90 M F bends 8 on the pipe sections 7 positioning them at 45 with respect to the module see box H fig 35 When installing a module ECONCEPT 51 51i use only one 90 bend and the cap contained in the starting kit fig 36 Fit the flue pipes together operation to be carried out on the ground en suring the alignment of the various connections 9 and respecting the coupling measurement of 705 mm see box L fig 36 Place the manifolds connected together on the support flanges and grad ually insert all the bends on the previously fitted diameter 100 pipe sec tions Check the correct angle of the manifold see fig 32 and the correct fitting of all the pipe sections bends and valves making sure the seals are prop fitted see box fig 36 Make the external seals adhere to the top of the modules Tighten and fix the support flanges Fit the manifold closing cap 10 Insert the condensate trap 11 and fix it to the special bracket 6 fitted in point G Connect the trap outlet to a condensate collection point e g the condensate manifold of the modules Use a special lubricant to facilitate the manifold connec
32. oiler fume outlet make sure the CO content in the fumes with the boiler operating at max and min output com plies with that given in the technical data table for the corresponding type of gas cod 35408572 11 2010 Rev 00 ECONCEPT 51 51i 101 101i fig 39 Gas conversion Activating TEST mode Press the heating buttons details 3 and 4 fig 1 at the same time for 5 seconds to activate TES1 moae ine boiler lights at the maximum heating power set as described in the following section The heating symbol detail 13 fig 1 and DHW symbol detail 9 fig 1 flash on the dis play the heating power will be displayed alongside fig 40 TEST mode heating power 100 To deactivate TEST mode repeat the activation sequence TEST mode is automatically disabled in any case after 15 minutes Only for model ECONCEPT 101 101i In TEST mode press the button detail 7 fig 1 to obtain the following operation Top boiler shell on bottom boiler shell off Top boiler shell off bottom boiler shell on Top boiler shell on bottom boiler shell on Heating power adjustment To adjust the heating power switch the boiler to TEST mode see sec 4 1 Press the heating buttons details 3 and 4 fig 1 to increase or decrease the power min 00 max 100 Press the reset button detail 8 fig 1 within 5 seconds the max power will remain that just set Exit the TEST mod
33. r Sales Technical Service FERROLI declines any liability for damage and or injury caused by unqualified and un authorised persons tampering with the unit 4 1 Adjustments Gas conversion The unit can operate on natural gas or LPG and is factory set for use with one of these two gases as clearly shown on the packing and on the dataplate Whenever a gas dif ferent from that for which the unit is arranged has to be used a conversion kit will be re quired proceeding as follows 1 Open the cabinet of the upper exchange body using the special key supplied 2 Loosen the gas valve fixing ring A 3 Undo the three fixing screws B and remove the gas valve 4 Replace the gas valve D with the one contained in the conversion kit positioning itinside the seal E Refit the parts and check their tightness Repeat steps 2 3 and 4 for the lower exchanger body model ECONCEPT 101 101ionly 6 Modify the parameter on the control system a putthe boiler in standby mode e press the DHW buttons details 1 and 2 fig 1 for 10 seconds the display shows P01 flashing e press the DHW buttons fig 1 details 1 and 2 to set parameter 00 for use with natural gas or 01 for use with LPG e press the DHW buttons details 1 and 2 fig 1 for 10 seconds the boiler will return to standby mode 7 Apply the label contained in the conversion kit near the dataplate 8 Using a combustion analyser connected to the b
34. r with the error code indi activating the sliding tem n 227 the sliding temperature cates which boiler shell is in fault status perature There are faults that cause permanent shutdown marked with the letter A to restore A41 Sensor positioning Delivery sensor detached Check the correct positioning and opera operation just press the RESET button detail 8 fig 1 for 1 second or RESET on the from the pipe tion of the heating sensor optional remote timer control if installed if the boiler fails to start it is necessary to firstly A42 Heating sensor fault Sensor damaged Replace the sensor eliminate the fault F42 Heating sensor fault Sensor damaged Replace the sensor Other faults marked with the letter F cause temporary shutdowns which are automat Sensor damaged ically reset as soon as the value returns within the boiler s normal working range Cascade temperature Ki F50 Wiring shorted Check the wiring or replace the sensor sensor fault Wiring di ted Table 4 Fault list D ontroller inter the earth connection and replace Faultcode Fault Possible cause Cure Ae GontrolerDEM12 fault nal error the controller if necessary Check the regular gas flow to the boiler No communication Controller not connected Connect the controller to the gas valve No gas and that the air has been eliminated from A62 between controller and the pipes gas valve Valve damaged Replace the valve lonition detection elec Check the wiring of
35. ramic premix burner housed in a vertical cabinet in AISI 316 stainless steel version ECONCEPT 51i 101i or in epoxy powder coated steel resistant to atmospheric agents version ECONCEPT 51 101 The plumbing circuits of the exchangers each equipped with its own local circulating pump run into system delivery and return manifolds inside the module The control sys tem has a microprocessor and user interface with a large display A cascade control unit available by request enables effective and economical manage ment of the modules ECONCEPT 51 511 101 101i connected in cascade The generators ECONCEPT 51 51i 101 101i are designed for installation even outside The versions ECONCEPT 51i 101i with stainless steel cabinet are particularly recom mended for places where the climatic and environmental conditions are unfavourable 2 2 Control panel 16 17 19 18 2023 5 11 21 Cc 6 8 fig 1 Control panel 14 24 7 The control panel is located inside the cabinet To access it open the front door with the special key supplied Key 1 DHW temperature setting decrease button with optional hot water tank in stalled 2 DHW temperature setting increase button with optional hot water tank in stalled 3 Heating system temperature setting decrease button 4 Heating system temperature setting increase button 5 Display 6 Summer Winter mode selection but
36. rating range Wi adjustment the temperature set with the heating buttons The boiler must be regulated at the time of installation by qualified personnel Adjust ments can in any case be made by the user to improve comfort Compensation curve and curve offset Press the button reset detail 8 fig 1 5 seconds to display the actual pensatinn be modified with the DHW buttons curva Ma TU which details 7 C and 2 fig 1 Adjust the required curve from 1 to 10 according to the characteristic fig 12 By setting the curve to 0 sliding temperature adjustment is disabled fig 10 Compensation curve Press the heating buttons gt E details 3 4 1 t access parallel curve offset fig 13 modifiable with the DHW buttons C details 1 and 2 fig 1 ce E fig 11 Curve parallel offset Press the button detail 8 fig 1 again for 5 seconds to exit parallel curve adjustment mode 7 If the room temperature is lower than the required value it is advisable to set a higher order curve and vice versa Proceed by increasing or decreasing in steps of one and check the result in the room 90 85 80 70 60 50 40 30 20 fig 12 Compensation curves OFFSET 20 OFFSET 40 20 10 0 10 20 fig 13 Example of compensation parallel curve offset 48 cod 35408572 11 2010
37. ter in the system If par tial or total emptying of the system becomes necessary in these cases it is advisable to refill with treated water Gas connection The gas must be connected to the corresponding union with a rigid metal pipe The gas meter must be adequate for the simultaneous use of all units connected to it Carry out the generator gas connection in accordance with current regulations The di ameter of the gas pipe leaving the generator does not determine the diameter of the pipe between the unit and the meter it must be chosen according to its length and pressure loss Make sure to install a fuel shutoff valve externally with respect to the modules enabling the gas to be turned off even without opening the single modules equipped with key closing Connection instructions ECONCEPT 51 51i 101 101i is equipped inside with 3 manifolds gas system delivery and return and a condensate drain pipe that facilitate cascade connection and also con nection of a single module to the system The manifolds are sized for connecting up to 5 modules in series The cabinet contains a set of flanges seals and screws for the con nection To connect a single module fig 16 After determining on which side of the module to make the water and gas connec tions connect the flanges with the joining section contained in the kit on that side after suitably welding them to the system pipes Make sure to correctly to fit the seals contained
38. the cab inet Make the electrical connections as shown in the wiring diagram on sec 47 and run the cables through the special cable glands 456789 1049 42777777 306 25 26 27 28 29 30 OO OQ qlqlolinlio 2505050 O 922799921 fig 26 Electrical terminal block 42 DHW temperature sensor not supplied 72 Room thermostat not supplied 72b Room thermostat not supplied 95 Diverter valve not supplied A Heating phase B DHW phase C Neutral NOTE For valves with 2 wires and spring return use the connections B and 130 DHW circulating pump not supplied 138 External probe not supplied 139 Remote timer control not supplied 298 Cascade temperature sensor not supplied 299 Input 0 10 Vdc 300 Burner lit contact voltage free contact 301 Fault contact voltage free contact 302 Remote reset input 230 Volt 306 Heating system circulating pump not supplied 307 Heating system second circulating pump not supplied For connection in cascade MAX 5 MODULES 1 Connect the modules as shown in fig 27 example with 4 modules A B D ki 26 28 29 20 26 27 28 a 30 26 a 28 ku 30 2n 2r 20 29 20 fig 27 Connection in cascade 1st Module 2nd Module 3rd Module 4th Module Carry out the electrical
39. the electrode and that A63 9 itis correctly positioned and free of any A64 Controller DBM12 inter Check the earth connection and replace trode fault deposit A65 Controller DBM12 fault troller if A01 No burner ignition eposits nal error e controller if necessary Check the gas valve and replace it if nec F66 Faulty gas valve essa i 5 TECHNICAL DATA AND CHARACTERISTICS nsufficient gas su pressure gaS SUPPY Check the gas supply pressure 5 1 Dimensions and connections Trap blocked Check the trap and clean it if necessary lo Flame present signal with Electrode fault Check the ionisation electrode wiring 1 o burner off Card fault Check the card H Heating sensor damaged Check he correct positioning and opera tion of the heating sensor A03 Gvertemperature prose No water circulation in the tion activation Check the circulating pump system Air in the system Vent the system A04 Fume extraction duct Fault F07 generated 3 See fault F07 safety device activation times in the last 24 hours A05 Fan protection activation Fauta generated ford See fault F15 hour consecutive lonisation electrode fault Check the position of the ionisation elec trode and replace it if necessary Flame unstable Check the burner No flame after ignition Gas valve Offset fault Check the Offset adjustment at minimum A06 stage 6 times in 4 min power utes Remove the obstruction from the flue air fume ducts obstructed fume extraction ducts
40. tions ECONCEPT 51 51i 101 101i 3 6 Condensate drain A Condensate drain connection using one generator The boiler has an internal condensate drain trap connected to an internal con densate outlet manifold et Ul fig 37 Condensate drain connection with one generator A Place the 240 pipe 1 not supplied on the side of the generator B Slide the pipe 2 towards the side of the arrow for at least 2 3 cm in order to in sert it in the pipe 1 Condensate drain connection using two or more generators kea 2 B fig 38 Condensate drain connection with several generators A Place the 240 pipe 1 not supplied on the side of the generator B Slide the pipe 2 of each generator towards the side of the arrow for at least 2 3 cm in order to insert it in the pipe 1 4 SERVICE AND MAINTENANCE adjustment conversion commissioning and maintenance operations described be low must only be carried out by Qualified Personnel meeting the professional technical requirements prescribed by current regulations such as those of the Local Afte
41. ton 7 Economy Comfort mode selection with optional hot water tank installed and unit On Off button 8 Reset button 9 DHW operation with optional hot water tank installed 10 Summer mode 11 Multifunction Ferroli 12 Eco Economy mode with optional hot water tank installed 13 Heating mode 14 Unit On Off button 15 Burner On 16 Appears on connecting the Remote Timer Control optional 17 Information symbol 18 Top boiler shell 19 Top boiler shell system fault reset request 20 Fault 21 Circulating pump On 22 Appears on connecting the external probe optional 23 Boiler Off 24 Bottom boiler shell 25 Bottom boiler shell system fault reset request model ECONCEPT 101 101ionly Indication during operation Heating A heating demand generated by the Room Thermostat or Remote Timer Control or 0 10 Vdc signal is indicated by activation of the circulating pump and the radiator details 13 and 21 fig 1 The display detail 11 fig 1 shows the actual heating delivery temperature and during heating standby time the message d Activation of the arrows details 18 and 24 fig 1 indicates which boiler shell is on fig 2 DHW with optional hot water tank installed A hot water tank heating demand is indicated by activation of the circulating pump and the tap details 9 and 21 fig 1 The display detail 11 fig 1 shows the actual hot water tank sensor temperature and during
42. uc tor FERROLI S p A C Adres Via Ritonda 78 a 37047 San Bonifacio VR declar c acest este conformitate cu urm toarele directive CEE Directiva Aparate cu Gaz 2009 142 Directiva Randament 92 42 Directiva Joas Tensiune 73 23 modificat de 93 68 Directiva Compatibilitate Electromagnetic 89 336 modificat de 93 68 Presedinte si reprezentant legal Cavaler al Muncii Dante Ferroli Ku FERROLI S p A anpec Via Ritonda 78 a 37047 San Bonifacio VR CEE 2009 142 92 42 73 23 93 68 89 336 93 68 Dante Feryoli
43. using the system switch and or the special cut off devices In case of a fault and or poor operation deactivate the unit and do not attempt to repair it or directly intervene Contact professionally qualified personnel Repair replacement of the products must only be carried out by professionally qualified using original spare parts Failure to comply with the above could affect the safety of the unit This unit must only be used for its intended purpose Any other use is considered improper and therefore dangerous The packing materials are potentially hazardous and must not be left within the reach of children The images given in this manual are a simplified representation of the product In this representation there may be slight and insignificant differences with respect to the product supplied 2 OPERATING INSTRUCTIONS 2 1 Introduction Dear Customer Thank you for choosing ECONCEPT 51 51i 101 101i heat generator of the latest gen eration FERROLIfeaturing advanced design and cutting edge technology Please read this manual carefully since it provides important information on safe installation use and maintenance ECONCEPT 51 51i 101 101i is a high efficiency modular premix condensing heat generator for heating with very low emissions running on natural gas or LPG and ar ranged for installation in cascade Each ECONCEPT 51 51i 101 101i module is equipped with a double aluminium lamel lar exchanger and double ce
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