Ferroli ECONCEPT 100 Fehlerbehebungshandbuch

ECONCEPT 100

premixed gas-fired heat generator

with condensation

INSTRUCTIONS FOR USE, INSTALLATION AND MAINTENANCE

ECONCEPT 100

IMPORTANT

Your "benchmark" Installation, Commissioning and Service Record Log Book is enclosed in the

last pages of this manual. “This record must be completed and left with the end user”.

Ferroli is a member of the Benchmark initiative and fully supports the aims of the programme.

Benchmark has been introduced to improve the standards of installation and commissioning of central

heating systems in the UK and to encourage the regular servicing of all central heating systems to

ensure safety and efficiency.

Please see installation and servicing guidelines.

• Read the warnings given in this manual thoroughly.

They provide important information for safe instal-

lation, use and maintenance

• The instruction manual, by law must be left with the

end user.

• If the appliance is sold or transferred to another

owner or if the owner moves, leaving the appliance

behind, always ensure that the manual is kept with

the appliance for consultation by the new owner

and /or installer.

• Incorrect installation or poor maintenance absolves

the manufacturer from all liability for damage to

persons and property.

• Installation and maintenance must be carried out

in accordance with current legislation, according

to the manufacturer’s instructions and by qualified

corgi registered engineer.

• Before service or maintenance work is carried out

isolate the appliance from the mains electricity

supply.

• In the event of malfunction or faulty operation, isolate

the appliance. Do not attempt to repair or carry out

any other operation on the appliance directly. Contact

Ferroli or a qualified engineer only.

• Repairs or the replacement of components must be

carried out exclusively by qualified personnel using

original spare partsonly. Failure toadhere to theabove

may compromise the safety of the appliance.

• To guarantee efficient operation, the appliance must

be serviced once a year by a Corgi registered engi-

neer.

• The appliance may not be used for purposes other

than those for which it was explicitly designed.

• Incorrect installation and use or failure to follow the

instructions provided by the manufacturer absolve

the manufacturer from all liability for damage.

• After unpacking, check that the contents are correct

and undamaged.

• Keep packing out of reach of children as it could be

potentially hazardous.

• To clean external parts, use a damp cloth moistened

with soapy water if necessary. Avoid using abrasive

cleaning products and solvents.

This symbol indicates “Caution” and is placed next to all safety information.

Strictly follow these instructions in order to avoid danger and damage to persons

or property.

This symbols calls attention to a note or important information, please read thou-

rougly.

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 90/396

• 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

Dante Ferroli

ECONCEPT 100

1. OPERATING INSTRUCTIONS .............................................................. 4

1.1 Introduction ................................................................................................. 4

1.2 Control panel ............................................................................................... 5

1.3 External control units................................................................................... 8

1.4 Switching on and off .................................................................................... 9

1.5 Anomalies..................................................................................................... 9

2. INSTALLATION.................................................................................. 10

2.1 General Instructions..................................................................................... 10

2.2 Connection in cascade................................................................................. 10

2.3 Place of installation ...................................................................................... 11

2.4 Gas and water connections ......................................................................... 11

2.5 Electrical Connections ................................................................................. 14

2.6 Flue connection............................................................................................ 16

2.7 Condensate drain......................................................................................... 16

3. SERVICE AND MAINTENANCE......................................................... 17

3.1 Adjustments ................................................................................................. 17

3.2 System start-up............................................................................................ 18

3.3 Maintenance................................................................................................. 20

3.4 Troubleshooting........................................................................................... 21

4 TECHNICAL CHARACTERISTICS AND DATA ..................................... 23

4.1 Dimensions and connections ....................................................................... 23

4.2 General view and main components ........................................................... 24

4.3 Technical data table..................................................................................... 25

4.4 Diagram of circulating pump losses of pressure / head ............................. 26

4.5 Wiring diagram ............................................................................................ 27

BENCHMARK ........................................................................................ 28

ECONCEPT 100

1. OPERATING INSTRUCTIONS

1.1 Introduction

Dear Customer,

Thank you for choosing Econcept 100, a FERROLI heat generator of the latest generation featuring ad-

vanced design and cutting-edge technology.

Econcept 100 is a high-efficiency modular heat generator for condensation premixed heating with very

low emissions, running on natural gas or LPG.

Each Econcept 100 module is equipped with a twin aluminium laminar exchanger and a twin ceramic

premixed burner contained in an upright cabinet made of AISI 316 stainless steel.

Each boiler shell (exchanger + burner) is governed by its own microprocessor control system with self-

diagnostics, able to work independently.

The user interface is easy to use with a keypad and display, making it possible to know appliance operating

status at any time. The operating parameters and historical data are stored internally and can be retrieved

via the interface with a Personal Computer to make Service operations easier.

The plumbing circuits of the exchangers, each equipped with its own local circulating pump, run into system

delivery and return manifolds inside the module.

A cascade control unit, available on request, enables effective and economical control of the two internal

boiler shells or several Econcept 100 modules connected in cascade.

Boiler shell

Cascade control

unit (on request)

Boiler shell 1 and 2

control panel

Fig. 1

ECONCEPT 100

OFFON

OFF

Display D1

boiler 1

Display D2/D3

boiler 1

Boiler 1

ignition button

(switches the top boiler shell on)

Display D1

boiler 2

Display D2/D3

boiler 2

Boiler 2

ignition button

(switches the bottom boiler shell on)

1.2 Control panel

From the control panel it is possible to display appliance operation status and set the operating parameters

of the two heat exchanger + burner shells inside the module.

At the control panel level, operation adjustment and display are entirely independent for the two internal

boiler shells.

Fig. 2

MODE key - Use to scroll the parameters.

RESET key - Use to reset generator operation in case of shutdown.

EDIT keys - Use to edit the settings.

CONFIRM key - Use to enable the setting value.

MODE display - Shows the generator operation mode or the selected parameter.

DATA display - Shows the parameter value

Key functions

Display information

ECONCEPT 100

Operating mode

Standby

Heating

Standby after heating op.

Display D1 Display D2/D3

System delivery temperature

Summer/Winter selection (00 = Summer  11 = Winter)

DO NOT HANGE THIS PARAMETER*

System delivery temperature display and setting

Not used

System return temperature display

Outside temperature display

Not used

Boiler power display

ompensation curve display and setting

Not used

DISPLAY D1 DISPLAY D2 - D3

Display of operation details

The display shows appliance status during operation, without pressing any keys:

Accessing the operational menu

Press the “ - mode” key to access the operation menu. Press the “ - mode” key again to display the

following parameters and information in sequence:

*Important: For correct generator operation this parameter must remain set at “00”.

ECONCEPT 100

2010 0 -10 -20

Outside tem

erature °

System delivery

temperature °

Adjustments

Setting the system temperature

To set the system delivery temperature on the single boiler shell, access the operational menu and press

the key to display parameter 1 - system delivery temperature. On pressing one of the keys, the

display starts flashing and the delivery temperature setpoint is displayed. Set the required value with the

keys. To activate the new setting, press the key. To cancel, do not press and press .

Summer/Winter selection

For the Summer/Winter selection, access the operation menu and press to display the parameter “0.”.

At parameter “0.”, press one of the keys to display the Summer/Winter selection (the parameter “0.”

flashes); by using the same keys it is possible to select Summer mode (set 00) or Winter mode (set 11). To

activate the new setting, press ; to exit without activating the selection, press .

In “Summer” mode (00) heating is off. The antifreeze function stays on.

Sliding Temperature

When the optional external sensor is installed the generator adjustment system works with “Sliding Tem-

perature”. In this mode, the temperature of the heating system is controlled according to the outside

weather conditions, to ensure a high degree of comfort and energy-saving throughout the year. In particular,

as the outside temperature increases the system delivery temperature decreases according to a specific

“compensation curve“.

With the Sliding Temperature adjustment, the temperature set in parameter 1 of the operation menu be-

comes the maximum system delivery temperature. It is advisable to set a maximum value to permit system

adjustment throughout its useful working range.

The generator must be regulated at the time of installation by qualified personnel. Possible adjustments

can in any case be made by the user to improve comfort: in fact the compensation curve can be modified

from the operation menu with the key and scrolling the menu with the key to parameter 9.

The set compensation curve is displayed (see graph below). On pressing one of the keys, the display

starts flashing and the required value can be set with the keys. To activate the new curve, press .

To cancel, do not press the and press .

If the room temperature is lower than the required value, it is advisable to set a higher curve and vice versa.

Proceed by increasing or decreasing in steps of one and check the result in the room.

Compensation curves

ECONCEPT 100

HG/SQ-2

Honeywell

ABS78 9101112131415161718

LNLLLN12

3456

-- COMMON --

JP7

043002X0

1.3 External control units

Cascade control unit (code 1KWMH18A)

A cascade control unit enabling advanced management of the two internal boiler shells is available on

request.

One control unit can manage up to 5 internal boiler shells.

Control unit/module combinations are given in the following table.

For the connection and operating instructions, refer to the manual supplied with the control unit.

Fig. 3a

Control unit 0÷10 Vdc (code 043002X0)

A control unit enabling system temperature adjustment of the single boiler shell according to a signal 0÷10

Vdc is available on request. Therefore 2 control units will be necessary for each heat generator. Control

unit/module combinations are given in the following table.

For the connection and operating instructions, refer to the manual supplied with the control unit.

Fig. 3b

No. of

ECONCEPT 100

modules

No. of control

units 0÷10Vdc

510

No. of

ECONCEPT 100

modules

No. of cascade

control units

IMPORTANT

“Sliding temperature” adjustment will not be available using this control unit.

ECONCEPT 100

1.4 Switching on and off

Ignition

Check that any external system shut-off valves are open. Open the gas cock ahead of the generators, turn

the main switch ON and press the ignition keys on the control panel. The boiler will run a self-test cycle

of approx. one minute, after which it is ready for operation. The burner switches on and off completely

automatically depending on system heat demands.

Switching off

In case of prolonged idle periods, close the gas cock ahead of the generators and disconnect the power

supply. In this case, also the boiler antifreeze protection, which switches on the burner for system tempera-

tures below 5°C, is deactivated.

Dangers of freezing

The best protection during extremely cold periods is to keep the boiler and users working so that

the entire system is involved. Alternatively, add antifreeze fluid to the system water, in the amount

recommended by the supplier according to the presumed minimum ambient temperature.

1.5 Anomalies

In case of operation problems or anomalies, the control unit of the single boiler shell activates flashing of

the corresponding display (with fault identification code) and a 230Vac output (to which a visual or acoustic

signalling device can be connected. See the electrical connections section).

Faults marked with the letter “F” cause temporary shutdowns that are automatically reset as soon as the

value returns within the generator’s normal working range.

Faults marked with the letter “A” cause a permanent generator shutdown resettable by the user. To restore

operation, press the key (reset).

If the problem persists, or for any other trouble, refer to the “troubleshooting” section in this manual for

further details and, if necessary, request the intervention of Qualified Personnel or the assistance centre.

In case of appliance fault and/or poor operation, switch it off, and do not make any attempt to repair

it or directly intervene. Contact authorized and professionally qualified personnel.

ECONCEPT 100

Safety

elements

GAS

DELIVERY

RET RN

Generators connected in this way can be considered a single “equivalent” heat generator with a total power

of N x 90.4 kW. All the requirements of current standards and regulations applicable to this “equivalent”

generator with total heating power of N x 90.4 kW must be met. In particular, the place of installation,

safety devices and fume extraction system must be adequate for the total heating power N x 90.4 of the

bank of Econcept 100 units.

It is pointed out that each Econcept 100 module is in fact a complete independent heat generator, equipped

with its own safety devices. In particular, each Econcept 100 module is equipped with a water pressure switch,

safety thermostat and electronic limiting device. In case of overtemperature, no water or no circulation in

the unit, the protection devices cause the unit to switch off or shut down, preventing its operation.

The installation instructions given in the following paragraphs concern both single modules and cascade

connections.

Fig. 4

2. INSTALLATION

2.1 General Instructions

This appliance must only be used for its intended purpose. This unit is designed to heat water to a tempera-

ture below boiling point at atmospheric pressure and must be connected to a heating system compatible

with its performance, characteristics and heating capacity. Any other use is considered improper.

THE GENERATOR MUST ONLY BE INSTALLED BY QUALIFIED PERSONNEL, IN ACCORDANCE

WITH ALL THE INSTRUCTIONS GIVEN IN THIS TECHNICAL MANUAL, THE PROVISIONS OF CUR-

RENT LAWS, THE PRESCRIPTIONS OF NATIONAL AND LOCAL STANDARDS, AND THE RULES

OF PROPER WORKMANSHIP.

Incorrect installation can cause damage or injury, for which the manufacturer declines any liability.

2.2 Connection in cascade

Econcept 100 is a heat generator designed to operate separately or in cascade. If the heating power re-

quired by the system exceeds 90.4 kW, two or more Econcept 100 generators can be connected in cascade

(max. 5 heat generators), as shown by way of example in the figure.

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