ECONCEPT 51 A

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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 is 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 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. 15 = 16 = 17 = 18 = 20 = 21 = 22 = 23 = 25 = Heating A heating demand (generated by the Room Thermostat or Remote Timer Control or 010 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 DHW standby time, the message "d". Burner On Appears on connecting the Remote Timer Control (optional) Information symbol Arrow symbol Fault Circulating pump On Appears on connecting the external probe (optional) Boiler Off Fault reset request

Indication during operation

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fig. 2 DHW circuit (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 heating standby time, the message "d".

2. OPERATING INSTRUCTIONS 2.1 Introduction Dear Customer, Thank you for choosing a ECONCEPT 51 A wall-mounted boiler featuring FERROLIadvanced design, cutting-edge technology, high reliability and quality construction. Please read this manual carefully since it provides important information on safe installation, use and maintenance. ECONCEPT 51 A is a high efficiency, low emissions sealed chamber premix condensing heat generator for heating, running on natural gas or LPG and equipped with a microprocessor control system. The boiler shell consists of an aluminium finned tube exchanger and a ceramic premix burner, equipped with electronic ignition and ionisation flame control, a modulating speed fan and a modulating gas valve. ECONCEPT 51 A is a heat generator arranged to operate alone or in cascade. 2.2 Control panel

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fig. 3 -

16 17 18

20 23

Exclude hot water tank (economy) Hot water tank temperature maintaining/heating can be excluded by the user. If excluded, domestic hot water will not be delivered. The hot water tank can be deactivated by the user (ECO mode) by pressing the button (detail 7 - fig. 1). In ECO mode the display activates the symbol (detail 12 - fig. 1). To activate COMFORT mode, press the button (detail 7 - fig. 1) again. 2.3 Lighting and turning off Boiler lighting Press the On/Off button (detail 14 fig. 1).

11 4 21 3 13
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22 2 1 9 12 15 25

10

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Key 1= 2= 3= 4= 5= 6= 7= 8= 9= 10 = 11 = 12 = 13 = 14 =

14

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fig. 1 - Control panel DHW temperature setting decrease button (with optional hot water tank installed) DHW temperature setting increase button (with optional hot water tank installed) Heating system temperature setting decrease button Heating system temperature setting increase button Display Summer/Winter mode selection button Economy/Comfort mode selection (with optional hot water tank installed) and unit On/Off button Reset button DHW operation (with optional hot water tank installed) Summer mode Multifunction Eco (Economy) mode (with optional hot water tank installed) Heating mode Unit On / Off button fig. 4 - Boiler lighting

For the following 120 seconds the display will show FH which identifies the heating system air venting cycle. During the first 10 seconds the display will also show the card software release (A = Display card software release / B = Controller software release). 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.

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ECONCEPT 51 A
Turning the boiler off Press the button (detail 7 - fig. 1) for 5 seconds. DHW temperature adjustment (with optional hot water tank installed) Use the DHW buttons (details 1 and 2 - fig. 1) to adjust the temperature from a min. of 10C to a max. of 65C.

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fig. 5 - 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 disabled. The antifreeze system remains activated. To relight the boiler, press the button (detail 7 fig. 1) again for 5 seconds. fig. 9 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
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fig. 6 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 winter, it is 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.

When the optional external probe is installed the corresponding symbol (detail 22 fig. 1) is activated on the control panel display (detail 5 - fig. 1). The boiler control system operates with "Sliding Temperature". In this mode, the heating system temperature is controlled according to the outside weather conditions, in order to ensure high comfort and energy saving throughout the year. In particular, the system delivery temperature is decreased as the outside temperature increases, according to a specific "compensation curve. With Sliding Temperature adjustment, the temperature set with the heating buttons (details 3 and 4 - fig. 1) becomes the maximum system delivery temperature. It is advisable to set a maximum value to allow system adjustment throughout its useful operating range. The boiler must be adjusted at the time of installation by qualified personnel. Possible adjustments can in any case be made by the user to improve comfort. Compensation curve and curve offset
reset Press the button (detail 8 - fig. 1) for 5 seconds, to display the actual compensation curve (fig. 10) which can be modified with the DHW buttons (details 1 and 2 - fig. 1).

2.4 Adjustments Summer/Winter Switchover Press the button detail 6 - fig. 1 for 1 second.

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.

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fig. 7 The display activates the Summer symbol detail 10 - fig. 1. The heating function is deactivated, 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 ond. Heating temperature adjustment Use the heating buttons (details 3 and 4 - fig. 1) to adjust the temperature from a min. of 20C to a max. of 90C. (detail 6 - fig. 1) again for 1 sec-

fig. 10 - Compensation curve Press the heating buttons (details 3 and 4 - fig. 1) to access parallel curve offset (fig. 13), modifiable with the DHW buttons (details 1 and 2 - fig. 1).

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fig. 8

fig. 11 - Curve parallel offset Press the button adjustment mode.

(detail 8 - fig. 1) again for 5 seconds to exit parallel curve

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ECONCEPT 51 A
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 10 9 8 7 6 5 4 3 2 1

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 A is a complete and independent heat generator, 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, preventing 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 combustion circuit is sealed with respect to the place of installation and therefore the unit can be installed in any room. However, the place of installation must be sufficiently ventilated to prevent the creation of any dangerous conditions in case of even small gas leaks. This safety precaution is required by EEC Directive no. 90/396 for all gas-fired units, including those with a so-called sealed chamber. The unit can also work with air drawn from the installation room (B type). In this case, the room must be provided with adequate ventilation, according to current regulations.

20

10

-10

-20

fig. 12 - Compensation curves

Therefore the place of installation must be free of dust, flammable materials or objects or corrosive gases. The room must be dry and not subject to freezing. The boiler is arranged for wall installation. Wall fixing must ensure a stable and effective support for the generator.

OFFSET = 40
10 9 8 7 6 5 4 3 2 1

A vided for removing the casing and for normal maintenance operations
3.3 Plumbing connections

If the unit is enclosed in a cabinet or mounted alongside, a space must be pro-

20

10

-10

-20

20

10

-10

-20

fig. 13 - Example of compensation parallel curve offset

A justments are managed according to that given in table 1.

If the Remote Timer Control (optional) is connected to the boiler, the above ad-

The heating capacity of the unit must be previously established by calculating the building's heat requirement according to the current regulations. The system must be provided with all the components for correct and regular operation. In particular, provide for all the protection and safety devices required by the current regulations for the complete modular generator. They must be installed on the hot water circuit delivery piping, immediately after the last module, within a distance not more than 0.5 metres, with no shutoff devices in between. The unit is not supplied with an expansion tank; its connection must therefore be carried out by the Installer.

B B

The safety valve outlet must be connected to a funnel or collection pipe to prevent water spurting onto the floor in case of overpressure in the heating circuit. Otherwise, if the discharge valve cuts in and floods the room, the boiler manufacturer cannot be held liable. Do not use the water system pipes to earth electrical appliances.

Heating temperature adjustment Adjustment can be made from the Remote Timer Control menu and the boiler control panel. DHW temperature adjustment (with optional hot water tank installed) Summer/Winter Switchover Eco/Comfort selection (with optional hot water tank installed) Adjustment can be made from the Remote Timer Control menu and the boiler control panel. 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 Economy 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 Comfort mode. In this condition it is possible select one of the two modes with the button detail 7 -fig. 1. Sliding Temperature 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.

Before installation, carefully wash all the pipes of the system to remove any residuals or impurities that could affect proper operation of the unit. Also, a filter must be installed on the system return piping to prevent impurities or sludge from the system clogging and damaging the heat generators. The filter must be installed when replacing generators in existing systems. The manufacturer declines any liability for damage caused to the generator by failure to install or inadequate installation of this filter.

Carry out the relevant connections according to the diagram in fig. 33 and the symbols given on the unit. System water charcteristics In the presence of water harder than 25 Fr (1F = 10ppm CaCO3), the use of suitably treated water is advisable in order to avoid possible scaling in the boiler. The treatment must not in any case reduce the hardness to values below 15F (Decree 236/88 for uses of water intended for human consumption). Water treatment is indispensable in the case of very large systems or with frequent replenishing of water in the system. If partial or total emptying of the system becomes necessary in these cases, it is advisable to refill it with treated water. Antifreeze system, antifreeze fluids, additives and inhibitors The boiler is equipped with an antifreeze system that turns on the boiler in heating mode when the system delivery water temperature falls under 6C. The device will not come on if the electricity and/or gas supply to the unit are cut off. If it becomes necessary, it is permissible to use antifreeze fluid, additives and inhibitors only if the manufacturer of these fluids or additives guarantees they are suitable for this use and cause no damage to the heat exchanger or other components and/or materials of the boiler unit and system. It is prohibited to use generic antifreeze fluid, additives or inhibitors that are not expressly suited for use in heating systems and compatible with the materials of the boiler unit and system.

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).
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fig. 14 - Low system pressure fault

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 COMPLIANCE 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 A is a high-efficiency heat generator arranged to operate alone or in cascade (bank). When two or more generators ECONCEPT 51 A 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 equivalent generator with total heating capacity must be met. In particular the place of instal-

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ECONCEPT 51 A
Hot water tank connection (Optional kit -) The optional kit - is available for connection to an external hot water tank. The kit, which comprises a circulating pump (ref. 130 - fig. 15), hot water tank probe (ref. S - fig. 15) and plumbing fittings, must be installed inside the boiler according to the instructions provided. Then connect to the fittings in the boiler. 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 alongside the plumbing diagrams. "Service Menu" The card Service Menu is accessed by pressing the Reset button for 10 seconds. Press the Heating buttons to select "tS", "In", "Hi" or "rE". tS means Transparent Parameters Menu, In Information Menu, Hi History Menu, and rE History Menu Reset. Select "tS" and press the Reset button. The card is equipped with 29 transparent parameters also modifiable from Remote Control (Service Menu). Press the Heating buttons to scroll the list of parameters in increasing or decreasing order. Press the DHW buttons to modify the value of a parameter: the change will be automatically saved. Press the Reset button to return to the Service Menu. Press the Reset button for 10 seconds to exit to 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 order. Press the DHW buttons to modify the value of a parameter: the change will be automatically saved. Press the Summer/Winter button for 10 seconds to exit the card System Type Menu. One direct heating circuit

S
130 10

I
179

B
210 11

Check/Change parameter P02 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

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10

209

I*

fig. 15 - Hot water tank connection kit 209 210 10 11 130 179 B I S DHW delivery Hot water tank return System delivery System return DHW pump kit Non-return valves (not supplied) Hot water tank (not supplied) ISPESL safety devices (not supplied) Hot water tank probe Outlined connections to be carried out by the installer.

298 D

306

A
fig. 16 One direct heating circuit and one DHW circuit with pump Check/Change parameter P02 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.

Plumbing circuit examples Key of examples I* ISPESL safety devices (When required - not supplied) D Hydraulic separator (not supplied) 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 (supplied with kit FZ4) TS Safety thermostat (not supplied) PZ Zone pump (not supplied) FZ4 Zone regulator

138

72/139

42 I*

130

298 D

306

B
fig. 17

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ECONCEPT 51 A
One direct heating circuit and one DHW circuit with diverter valve Check/Change parameter P02 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. Two mixed heating circuits, one direct heating circuit and one DHW circuit with pump Check/Change parameter P02 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 regulator" handbook
FZ4

138 72/139
138

72/139

72/139

72/139

Zona 1

Zona 2

Zona 3

42 TS TS

42 I*

I* PZ SM M M PZ SM

PR

130

298 D

298 D

306

95

fig. 21

C
fig. 18 Two direct heating circuits Check/Change parameter P02 of the "Transparent Parameters Menu" to 1. Change parameter P.01 of the "System Type Menu" to 4. Change parameter P.02 of the "System Type Menu" to 1. Change parameter P.09 of the "System Type Menu" to 1.

3.4 Electrical connections Connection to the electrical grid

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.

138 72/139 72b

The boiler is prewired and provided with a Y-cable and plug for connection to the electricity 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 respect 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.

B
I* 307 306 298 D

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 personnel. If changing the electric power cable, use solely HAR H05 VV-F 3x0.75 mm2 cable with a maximum outside diameter of 8 mm. CAUTION: The room thermostat must have clean contacts. CONNECTING 230 V. TO THE TERMINALS OF THE ROOM THERMOSTAT WILL IRREPARABLY DAMAGE THE ELECTRONIC CARD. When connecting a remote timer control or a timer switch, do not take the power 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.

Room thermostat (optional)

B
D

fig. 19 Two mixed heating circuits and one direct heating circuit Check/Change parameter P02 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. For the electrical connection and the zone system settings, refer to the "FZ4 zone regulator" handbook
FZ4

138

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72/139

72/139

Zona 1

Zona 2

Zona 3

TS

TS

I* PZ SM M M PZ SM

PR

298 D

fig. 20

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ECONCEPT 51 A
Accessing the electrical terminal block The electrical terminal block is located inside a sealed box at the bottom left of the cabinet. Make the electrical connections as shown in the wiring diagram on fig. 37 and run the cables through the special cable glands. For connection in cascade 1. Connect the modules as shown in fig. 23

A
25 26 27 28 29 30 31 32

B
25 26 27 28 29 30 31 32

C
25 26 27 28 29 30 31 32

D
25 26 27 28 29 30 31 32

fig. 23 - Connection in cascade

A B C D
8 9 10 11 12

1st Module 2nd Module 3rd Module 4th Module

306

25 26 27 28 29 30 31 32

2. 3. 4. 5.

Carry out all the electrical 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 at 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

((

300 302

301 95
13 14 15 16

130/307

256

17 18 19 20 21 22 23 24

If this does not occur, disconnect the power and check the wiring in fig. 23. Settings All adjustments must be made on module no. 1. Possible faults If the electrical connection of a module is disconnected for any reason, module 1 will activate fault F70. If the electrical connection of a module is disconnected for any reason, the next module will activate fault F71. 3.5 Fume ducts The unit is a "C type" with sealed chamber and forced draught, the air inlet and fume outlet must be connected to one of the following extraction/suction systems. The unit is approved to operate with all the Cxy and Bxy flue configurations given on the dataplate (some configurations are given by way of example in this section). Some configurations may be expressly limited or not permitted by law, standards or local regulations. Before proceeding with installation, check and carefully observe the above-mentioned prescriptions. Also, comply with the provisions on the positioning of wall and/or roof terminals and the minimum distances from windows, walls, ventilation openings, etc.

72 299 139 138 298 72B 42

fig. 22 - Electrical terminal block 42 72 72b 95 DHW temperature sensor (not supplied) Room thermostat (not supplied) Room thermostat (not supplied) Diverter valve (not supplied) A = Heating phase B = DHW phase C = Neutral 130 138 139 256 298 299 300 301 302 306 307 NOTE: For valves with 2 wires and spring return, use the connections B and C DHW circulating pump (not supplied) External probe (not supplied) Remote timer control (not supplied) Modulating heating circulating pump signal Cascade temperature sensor (not supplied) Input 0 -10 Vdc Burner lit contact (voltage-free contact) Fault contact (voltage-free contact) Remote reset input (230 Volt) Heating system circulating pump (not supplied) Heating system second circulating pump (not supplied)

This C-type unit must be installed using the inlet and fume outlet ducts supplied by the manufacturer in accordance with UNI-CIG 7129/92. Failure to use them automatically invalidates every warranty and relieves the manufacturer of any liability. For fume exhaust pipes longer than 1 metre, during installation take in account

A the natural expansion of the materials when the boiler is operating.

To prevent deformations, leave an expansion space of approx. 2 4 mm for every metre of pipe.

fig. 24 - Expansion

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ECONCEPT 51 A
Connection with coaxial pipes Table. 4 - Accessories
Losses in meq Air inlet 1.0 1.2 1.5 0.3 2.0 Fume exhaust Vertical Horizontal 1.6 2.0 1.8 2.0 0.3 5.0

80

C13

C33

C33

C33

C13

C13

fig. 25 - Examples of connection with coaxial pipes (

= Air /

= Fumes)

PIPE 1 m M/F BEND 45 M/F 90 M/F PIPE SECTION with test point TERMINAL air, wall fumes, wall with antiwind

1KWMA83W 1KWMA65W 1KWMA01W 1KWMA70W 1KWMA85A 1KWMA86A

For coaxial connection, fit the unit with one of the following starting accessories. For the wall hole dimensions, refer to fig. 33. Any horizontal sections of the fume exhaust must be kept sloping slightly towards the boiler, to prevent possible condensate from flowing back towards the outside and causing dripping.
1000 100 60 125 80

3.6 Condensate drain connection The boiler is equipped with an internal trap C for condensate draining. Fit the inspection union A on the trap, also fitting seal B. Press the flexible tube D on about 3 cm and secure it with a clamp. Fill the trap with approx. 0.5 l. of water and connect the flexible tube to the drainage system. 1. Fit the inspection union A on the trap, also fitting seal B. Press the flexible tube D on about 3 cm and secure it with a clamp. Fill the trap with approx. 0.5 l. of water. Connect the flexible tube to the drainage system.

159 124

75

136

2. 3.

100

29

60

80

80

30

107

80

C
C

fig. 26 - Starting accessory for coaxial ducts A - Kit 60/100 - 1KWMR53A B - Kit 60/100 - 1KWMA71W C - Kit 80/125 - 1KWMA74Y Before carrying out installation, check with table 2 that the maximum permissible length is not exceeded, taking into account that every coaxial bend gives rise to the reduction indicated in the table. For example, a 80/125 duct comprising a 90 bend + 1 horizontal metre has a total equivalent length of 1.5 metres. Table. 2 - Max. length coaxial ducts
Coaxial 60/100 Max. permissible length Reduction factor 90 bend Reduction factor 45 bend 2m 1m 0.5 m Coaxial 80/125 12 m 0.5 m 0.25 m

B A

1
fig. 28 - Condensate drain connection 4. SERVICE AND MAINTENANCE

All adjustment, conversion, startup and maintenance operations described below must only be carried out by Qualified Personnel (meeting the professional technical requirements prescribed by current regulations) such as those of the Local After-Sales Technical Service. FERROLI declines any liability for damage and/or injury caused by unqualified and unauthorised 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 different gas to that for which the unit is arranged has to be used, a conversion kit will be required, proceeding as follows: 1. 2. 3. 4. Loosen the gas valve fixing ring "A". Remove the seal "E" and replace gas nozzle "D" with the one contained in the conversion kit. Refit the parts and check the tightness. Modify the parameter on the control system. 5. 6. put the boiler in standby mode press the DHW buttons (details 1 and 2 - fig. 1) for 10 seconds: the display shows "P01" flashing. Press the DHW buttons (details 1 and 2 - fig. 1) to set parameter 00 (for natural gas operation) or 01 (for LPG operation). press the DHW buttons (details 1 and 2 - fig. 1) for 10 seconds. the boiler will return to standby mode

Connection with separate pipes

C53

C33

C53

B23

C13

fig. 27 - Examples of connection with separate pipes ( Separate 80 ducts can be connected directly to the unit.

= Air /

= Fumes)

Before proceeding with installation make sure the maximum permissible length has not been exceeded, by means of a simple calculation: 1. 2. 3. Completely establish the layout of the system of split flues, including accessories and outlet terminals. Consult the table 4 and identify the losses in meq (equivalent metres) of every component, according to the installation position. Check that the sum total of losses is less than or equal to the maximum permissible length in table 3.

Apply the label, contained in the conversion kit, near the dataplate. Using a combustion analyser connected to the boiler fume outlet, make sure the CO2 content in the fumes, with the boiler operating at max. and min. output, complies with that given in the technical data table for the corresponding type of gas.

Table. 3 - Max. length separate ducts

A E D

fig. 29 - Gas conversion

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ECONCEPT 51 A
TEST mode activation Press the heating buttons (details 3 and 4 - fig. 1) at the same time for 5 seconds to activate the TEST mode. The 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 display; the heating power will be displayed alongside. 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 solvents.

A cloth, possibly soaked in soapy water. Do not use any abrasive detergents and
Opening the casing To open the boiler casing (fig. 31): 1. 2. 3. Undo the screws (1) Lift the casing (2) Turn and remove the casing (3)

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fig. 30 - TEST mode (heating power = 100%) To deactivate the TEST mode, repeat the activation sequence. The TEST mode is automatically disabled in any case after 15 minutes. 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).
reset Press the button (detail 8 - fig. 1) within 5 seconds; max. power will remain that just set. Exit TEST mode (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 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. Fill the 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 boiler. Check correct connection of the electrical system and efficiency of the earthing system 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 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 sure the water is circulating properly between the boiler and the systems. Make sure the gas valve 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 CO2 content in the fumes, with the boiler operating at max. and min. output, corresponds 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. Check the correct programming of the parameters and carry out any necessary customization (compensation curve, power, temperatures, etc.).

Checks during operation

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 function 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 obstructions. The burner and exchanger must be clean and free of scale. When cleaning, do not use chemical products or wire 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. The circulation pump must not be blocked. The expansion tank must be filled.

IIIIIII
eco comfort

II

II

IIIIIII

3 1
fig. 31 - Opening the casing Combustion analysis Combustion can be analysed through the air sampling point (detail 2) and fume sampling point (detail 1) shown in fig. 32. To take the measurement, it is necessary to: 1. 2. 3. 4. 5. Open the air and fume sampling points Insert the probes Press the "+" and "-" buttons for 5 seconds to activate the TEST mode Wait 10 minutes for the boiler to stabilise Take the measurement

For natural gas the CO2 reading must be between 8.7 and 9%. For LPG the CO2 reading must be between 9.5 and 10%.

Analyses made with an unstabilised boiler can cause measurement errors.

2 1 2 1

fig. 32 - Combustion analysis 4.4 Troubleshooting Diagnostics The boiler is equipped with an advanced self-diagnosis system. In case of a boiler fault, the display will flash together with the fault symbol (detail 20 - fig. 1) indicating the fault code. There are faults that cause permanent shutdown (marked with the letter A): to restore operation, press the RESET button (detail 8 - fig. 1) for 1 second or RESET on the optional remote timer control if installed; if the boiler fails to start, it is necessary to firstly eliminate the fault. Faults marked with the letter F cause temporary shutdowns that are automatically reset as soon as the value returns within the boiler's normal working range.

cod. 3540S560 - 03/2009 (Rev. 00)

EN

45

ECONCEPT 51 A
Table of faults Table. 5 - List of faults
195 120 120 195
120

5. TECHNICAL DATA AND CHARACTERISTICS 5.1 Dimensions and connections

Fault code

Fault

Possible cause No gas Ignition/detection electrode fault

Cure Check the regular gas flow to the boiler and that the air has been eliminated from the pipes Check the wiring of the electrode and that it is correctly positioned and free of any deposits Check the gas valve and replace it is necessary Check the gas supply pressure Check the trap and clean it if necessary Check the ionisation electrode wiring Check the card Check the correct positioning and operation of the heating sensor
630

A01

No burner ignition Faulty gas valve Insufficient gas supply pressure Trap blocked Flame present signal with Electrode fault burner off Card fault Heating sensor damaged

A02

A03

Overtemperature protection activation

No water circulation in the Check the circulating pump system Air in the system Vent the system
720

A04 A05

Fume extraction duct safety device activation Fan protection activated

Fault F07 generated 3 See fault F07 times in the last 24 hours Fault F15 generated for 1 See fault F15 hour (consecutive) Ionisation electrode fault Flame unstable Check the position of the ionisation electrode and replace it if necessary Check the burner Check the Offset adjustment at minimum power
380

A06

No flame after ignition stage (6 times in 4 minutes)

Gas valve Offset fault

Remove the obstruction from the flue, air/fume ducts obstructed fume extraction ducts and air inlet and terminals Trap blocked Flue partially obstructed or insufficient Fume sensor position Sensor damaged Check the trap and clean it if necessary Check the efficiency of the flue, fume extraction ducts and outlet terminal Check the correct positioning and operation of the fume sensor Check the wiring or replace the sensor

45

270

250

65

F07

High fume temperature

F10

Delivery sensor 1 fault

Wiring shorted Wiring disconnected Sensor damaged

F11

Return sensor fault

Wiring shorted Wiring disconnected Sensor damaged

Check the wiring or replace the sensor

166

50

1
Check the wiring or replace the sensor

fig. 33 - Dimensions and connections 1= 3= 5= System delivery - 3/4 Gas inlet - 3/4 System return - 3/4

F12

DHW sensor fault

Wiring shorted Wiring disconnected Sensor damaged

F13

Fume sensor fault

Wiring shorted Wiring disconnected Sensor damaged

Check the wiring or replace the sensor

5.2 General view and main components

F14

Delivery sensor 2 fault

Wiring shorted Wiring disconnected No 230V power supply

Check the wiring or replace the sensor Check the wiring of the 3-pin connector Check the wiring of the 5-pin connector Check the fan Check the electrical system Check the electrical system Fill the system
278 5 81 82 22 19 186 196 36

F15

Fan fault

Tachometric signal interrupted Fan damaged

F34 F35

Supply voltage under 170V Faulty mains frequency Incorrect system water pressure

Electric mains trouble Electric mains trouble Pressure too low Water pressure switch damaged or not connected

F37

Check the sensor

Probe damaged or wiring Check the wiring or replace the sensor shorted F39 External probe fault Probe disconnected after Reconnect the external probe or disable activating the sliding temthe sliding temperature perature Delivery sensor disconnected from the pipe Sensor damaged Controller not connected Damaged valve Check the correct positioning and operation of the heating sensor Replace the sensor Connect the controller to the gas valve Replace the valve
10 7 44 193 145 11

A41 F42 A62

Sensor positioning Heating sensor fault No communication between electronic controller and gas valve

114

32

fig. 34 - General view

46

EN

cod. 3540S560 - 03/2009 (Rev. 00)

ECONCEPT 51 A
5.3 Plumbing circuit 5.4 Technical data table The column on the right gives the abbreviation used on the dataplate.

16 191 278 161

196

Efficiency Pmax (50-30C) Efficiency Pmin (50-30C) Efficiency 30% Gas supply pressure G20 Max. gas delivery G20 Min. gas delivery G20 Gas supply pressure G31 Max. gas delivery G31 Min. gas delivery G31

186 114 36

193 210

154 44

32 14

Efficiency class Directive 92/42 EEC NOx emission class Max. working pressure in heating Min. working pressure in heating Max. heating temperature Heating water content Protection rating Power supply voltage Electrical power input

bar bar C litres IP V/Hz W kg 5 6 0.8 95 2.7 X5D 230V/50Hz 190 57 C13-C23-C33C43-C53-C63C83-B23-B33 0063AS4812 (tmax) (NOx) (PMS)

10

11

fig. 35 - Plumbing circuit Key fig. 34 and fig. 35 5 Sealed chamber 7 Gas inlet 10 System delivery 11 System return 14 Safety valve 16 Fan 19 Combustion chamber 22 Burner 32 Heating circulating pump 36 Automatic air vent 44 Gas valve 81 Ignition electrode 82 Detection electrode 114 Water pressure switch 145 Pressure gauge 154 Condensate outlet pipe 161 Condensing heat exchanger 186 Return sensor 191 Fume temperature sensor 193 Trap 196 Condensate tray 210 Hot water tank return 278 Double sensor (Safety + Heating)

Empty weight Type of unit

PIN CE

5.5 Diagrams Circulating pump head / pressure losses

3 2

5 A 4 1 3

0 0 500 1.000 1.500 2.000 2.500

Q [l/h]

fig. 36 A 1-2-3 Boiler pressure losses Circulating pump speed

cod. 3540S560 - 03/2009 (Rev. 00)

EN

47

ECONCEPT 51 A
5.6 Wiring diagram
82 81 44
DBM12KA

V1 V2

16

X1

32

X3

278
T T

191 16 98

306

186

X2

114

FUSE 3.15A

130/307
4 5 6 7 8 9 10 11 12 B C

L N

230V 50Hz
302

((

300

301

95

13 14 15 16

17 18 19 20 21 22 23 24

25 26 27 28

29 30 31 32

72 299 139 138 298 72B 155

256

2 5

10

11

12

10

X01

X04

X03

X05

DSP12A

fig. 37 - Wiring diagram Key fig. 37 16 Fan 32 Heating circulating pump 44 Gas valve 72 Room thermostat (not supplied) 72b Second room thermostat (not supplied) 81 Ignition electrode 82 Detection electrode 95 Diverter valve (not supplied) A = Heating phase B = DHW phase C = Neutral 98 114 130 138 139 155 186 191 256 278 298 299 300 301 302 306 307 NOTE: For valves with 2 wires and spring return, use the connections B and C Switch Water pressure switch DHW circulating pump (not supplied) External probe (not supplied) Remote timer control (not supplied) Hot water tank temperature probe (not supplied) Return sensor Fume temperature sensor Modulating heating circulating pump signal Double sensor (Safety + Heating) Cascade temperature sensor (not supplied) Input 0-10 Vdc Burner lit contact (voltage-free contact) Fault contact (voltage-free contact) Remote reset input (230 Volt) Heating system circulating pump (not supplied) Heating system second circulating pump (not supplied)

48

EN

cod. 3540S560 - 03/2009 (Rev. 00)