Ferroli Econcept 50 A Installation And Operating Instructions Manual

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ECONCEPT 50 A

WALL-HUNG, PRE-MIX

GAS-FIRED CONDENSING BOILER

INSTALLATION

AND

OPERATING INSTRUCTIONS

Appr. nr. B99.15 A - CE 0063 BL 3475

cod. 3544205/0 ediz. 11/2002

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ECONCEPT 50 A

IMPORTANT

Your “benchmark” Installation, Commissioning and Service Record Log Book will be enclosed in
your customer information pack.
“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 guidlines.

CE MARK

CE mark documents that the Ferroli gas appliances comply with the requirement contained in
European directives applicable to them.
In particular, the appliances comply with the following CEE directives and the technical specifications
provided from them:

• Gas appliances directive 90/396

• Efficiencies directive 92/42

• Low tension directive 73/23 (modified from the 93/68)

• Electromagnetic compatibility directive 89/396 (modified from the 93/68)

INSTRUCTIONS AND REGULATIONS

Assembly, installation, first start up and maintenance must be carried out by competent persons only,
in accordance with all current technical regulations and directives.

c.o.s.h.h.
Materials used in the manufacture of this appliance are non hazardous and no special precautions are
required when servicing.

Related Documents

This appliance must be installed strictly in accordance with these instructions.
The Gas Safety Regulations (Installations & Use) 1996.
The Local Building Regulations.
The Building Regulations.
The Buildings Standards (Scotland - Consolidated) Regulations.

British Standards Codes of Practice:

B.S. 7593 1992 TREATMENT OF WATER IN DOMESTIC HOT WATER CENTRAL HEATING
SYSTEMS
B.S. 5546 1990 INSTALLATION OF HOT WATER SUPPLIES FOR DOMESTIC PURPOSES
B.S. 5440 Part 1 2000 FLUES
B.S. 5440 Part 2 1989 AIR SUPPLY
B.S. 5449 1990 FORCED CIRCULATION HOT WATER SYSTEMS
B.S. 6798 1987 INSTALLATION OF GAS FIRED HOT WATER BOILERS
B.S. 6891 1989 GAS INSTALLATIONS
B.S. 7671 1992 IEE WIRING REGULATIONS
B.S. 4814 1990 SPECIFICATION FOR EXPANSION VESSELS
B.S. 5482 1994 INSTALLATION OF LPG

Model Water Bye Laws

For Northern Ireland the rules in force apply

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Econcept 50 A

• Read the warnings given in this manual
thoroughly. They provide important in­formation for safe installation, use and
maintenance

• Keep the manual safe for future consul­tation.

• The instruction manual is an integral and
essential part of the product and must
be kept by the 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 or
property.

• Installation and maintenance must be
carried out and conform with current
legislation, according to the manufac­turer’s instructions and by qualified per­sonnel.

• 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 complete and undamaged.

• Keep packing out of reach of children as
it may be potentially hazardous.

• To clean external parts, use a damp
cloth moistened with soapy water if nec­essary. Avoid using abrasive cleaning
products and solvents.

• Before cleaning or maintenance, dis­connect the appliance from the mains
via the switch on the appliance or a
suitable isolating device.

• 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 qualified personnel only.

• Repairs or the replacement of compo­nents must be carried out exclusively by
qualified personnel using original spare
parts only. Failure to respect the above
my compromise the safety of the appli­ance.

• To guarantee efficient operation, the
appliance must be serviced once a year
by an authorised service centre.

• The appliance may not be used for pur­poses other than those for which it was
explicitly designed. Any other use is
considered improper and therefore dan­gerous.

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ECONCEPT 50 A

1. CHARACTERISTICS AND TECHNICAL DATA .................................. 5

1.1 Introduction ................................................................................................. 5

1.2 Boiler control panel ..................................................................................... 5

1.3 Ignition and Shut-down ............................................................................... 6

1.4 Regulations .................................................................................................. 7

1.5 Maintenance ................................................................................................ 8

1.6 Fault codes .................................................................................................. 8

2. INSTALLATION ................................................................................ 9

2.1 General Instructions .................................................................................... 9

2.2 Positioning and wall mounting .................................................................... 9

2.3 Connection to the hydraulic system.......................................................... 10

2.4 Connection to the gas system................................................................... 11

2.5 Electrical connections ................................................................................ 12

2.6 Flues........................................................................................................... 14

2.7 Condensation discharge connection ......................................................... 19

2.8 Modular installation ................................................................................... 20

3. SERVICE AND MAINTENANCE .................................................... 22

3.1 Settings ...................................................................................................... 22

3.2 Commissioning and testing ....................................................................... 23

3.3 Maintenance .............................................................................................. 25

3.4 Troubleshooting......................................................................................... 26

4. OPERATING INSTRUCTIONS ........................................................ 28

4.1 Dimensions and connections ..................................................................... 28

4.2 General view and main components ......................................................... 29

4.3 Technical data table ................................................................................... 30

4.4 Diagrams .................................................................................................... 31

4.5 Wiring diagrams ........................................................................................ 32

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Econcept 50 A

1. CHARACTERISTICS AND TECHNICAL DATA

1.1 Introduction

Dear Customer,
Thank you for having chosen the Econcept 50 A, the latest generation of FERROLI wall-hung boiler, featuring

advanced design and cutting-edge technology.
The Econcept 50 A is a pre-mix condensing thermal generator for heating , with very high thermal efficiency

and very low emissions, fired by natural gas or LPG.
The boiler can be connected with external DHW storage.
The boiler control and regulation system is microprocessor-based, with advanced self-diagnostics. The user

interface, made up of a keypad and display, is user-friendly, and shows the operating status of the appliance
at all times. (The operating parameters and the data logs are saved internally and can be called up using the
Personal Computer interface to simplify Service operations).

The heat output is regulated continuously across the entire operating range (also with DHW storage), with
temperature-scrolling climate control, which automatically adapts the operating mode to the characteristics
of the internal and external environment, of the building and its location, using external and internal sensors
(optional extra).

1.2 Boiler control panel

Function of the buttons

MODE button - Use this button to scroll the parameters.

RESET button - Use this button to reset the operation of the boiler in the event of shut-

MODIFY button - Use these buttons to modify the regulation values.

CONFIRM button - Use this button to enable the set regulation value.

fig. 1

down.

Display D3

Display D2Display D1

Ignition
switch

Display indications

D1

MODE display - Indicates the operating mode of the boiler or the selected parameter.

D2 D3

DATA display - Indicates value of the parameters

Led L1 - Indicates:Economy Operation

Led L2 - Indicates:Comfort Operation

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Econcept 50 A

Operating indications on the display

During operation, without pressing any of the buttons the display shows the operating status of the
appliance:

Operating mode

Display “D1” Display “D2/D3”

Standby

Heating

Domestic hot water

Standby following domestic hot water op.

Standby following heating op.

Waiting for DHW production

Central heating outlet temperature

Central heating outlet temperature

Domestic hot water temperature

Domestic hot water temperature

Central heating outlet temperature

Domestic hot water temperature

Note: when the burner fires a small. Will appear in display D1 after the letter.

Accessing the operating menu

Pressing the “ - mode” button once accesses the operating menu. Pressing the “ - mode” button again
displays the following parameters and information in sequence:

DISPLAY D1 DISPLAY D2/D3

Summer/Winter Selection (00 = Summer - 11 = Winter)
Economy/Comfort Selection (0 = Economy - 1 = Comfort)
CH outlet temperature view and setting
Display and setting DHW storage temperature
Display system return temperature
External temperature
Flue gas temperature

-

­Boiler power
Compensation curve setting

-

1.3 Ignition and Shut-down

Ignition

Check that any shut-off valves in the heating system and domestic hot water circuit outside of the boiler are
open. Open the gas control upstream from boiler and press the main switch. The boiler will perform a self­test cycle lasting approximately one minute, at the end of which it is ready for operation. The ignition and
shut-down of the burner assembly are completely automatic operations, which depend on the requirements
of the heating system or domestic hot water circuit (display should read "FHI" during test).

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Econcept 50 A

Shut-down

In the event of extended periods of inactivity close the gas control upstream from the boiler and disconnect
the electrical power supply to the appliance. In this case, the boiler antifreeze protection function is also
disabled; this function switches on the burner assembly when the heating system temperature falls below
5°C.

For extended periods of inactivity during the winter months, in order to avoid damage due to
freezing, all the water should be drained from the boiler, both the domestic hot water and the heating
system; alternatively, drain only the domestic hot water and introduce antifreeze into the heating
system.

For short periods of inactiviti leave the power and gas turned on, the frost protection will activate
if the appliance falls below 5°C, however, this will only protect the appliance. For system protection
internal and external frost stat.

1.4 Regulations

Setting the heating system temperature

Set, using the room thermostat or remote control, the desired temperature inside the rooms. When acting
on the room thermostat, the boiler is turned on and the heating system water is brought to the central heating
outlet set temperature or calculated temperature (with temperature scrolling active). On reaching the
required temperature inside the rooms, the boiler will switch off.

If no room thermostat or remote control is installed, the boiler will maintain the heating system temperature
at the central heating outlet setpoint.

To set the central heating outlet temperature, access the operating menu, and using the button display
parameter 1 – central heating outlet temperature. On pressing one of the buttons the display will start
to flash, showing the outlet temperature setpoint. Use the buttons to set the required value. To
activate the new value, press the button . To cancel the setting, do not press the button , and press

the button .

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Econcept 50 A

Outside temperature compensation

When the (optional) external probe is installed, the boiler regulation system functions in “Outside
temperature compensation” mode. In this mode, the temperature of the heating system is regulated
according to the external climatic conditions, so as to guarantee a high degree of comfort and energy saving
all year round. Specifically, when the external temperature falls, the central heating outlet temperature is
increased, according to a pre-determined “compensation curve”.

In this mode, the temperature set in parameter 1 of the operating menu becomes the maximum central
heating outlet temperature. This should be set to Maximum to allow the system to regulate over the entire
working range.

The boiler must be set during installation by qualified personnel. Other minor modifications can be made by
the user to improve the level of comfort: the compensation curve can in fact be modified by accessing the

operating menu with the button and scrolling the menu, again using the button, to parameter 9.
The set compensation curve is displayed (refer to graph below). Pressing one of the buttons the display

starts to flash; use the buttons to set the required value. To activate the new curve, press the button

. To cancel the setting, do not press the button, and press the button .

If the ambient temperature is lower than the required value, it is suggested to set a higher curve, and vice­versa. Proceed with single unit increments or decreases, and check the results in the room.

Compensation curve

90

80

70

60

50

Temperatura

40

30

di mandata impianto C°

20

20 10 0 -10 -20

10

Temperatura esterna °C

9

8

7

6

5

4

3

2

1

1.5 Maintenance

This appliance must be serviced anually by an approved corgi engineer.
The casing, the control panel and the aesthetic parts of the boiler can be cleaned using a soft and damp cloth.

Do not use abrasives or solvents.

1.6 Fault codes

In the event of operating problems, the display flashes and shows the code identifying the fault code.
The display D1 is marked by the letter “F” and will temporary shut-down, this will reset automatically as soon

as the value returns within the boiler’s normal operating range.
The display marked by the letter “A” causes a shut-down of the boiler which can be reset by the user. To reset
operation, press the (reset) button.

If the problem persists, or for diagnosis if the fault codes (page 26), please refer to the “troubleshooting”
chapter in this manual for more details.

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Econcept 50 A

A A

B

D

C

2. INSTALLATION

2.1 General Instructions

Gas Safety (Installation & Use) Regulations: 1996
In the interest of safety, it is the law that all gas appliances are installed by a competent person in accordance

with the above Regulations, Building Regulations/Building Standards Scotland, Codes of Practice, current
I.E.E. Regulations and the byelaws of the Local Water Undertaking. Failure to comply with the Regulations
may lead to prosecution; it is your responsibility to ensure that the law is complied with.

N.B. For Northern Ireland the rules in force apply.
IMPORTANT: If the boiler is to be fitted in a timber framed building it should be fitted in accordance with

the Institute of Gas Engineers document IGE/UP/7. If in doubt advice should be sought from the Local
Supplier.

2.2 Positioning and wall mounting

The place of installation must be free of flammable objects or materials, corrosive gas, dust or volatile
substances. The environment must be dry and not exposed to rain, snow or frost.

The installation of the ECONCEPT must be on a suitable non-combustible load bearing wall which will provide
an adequate fixing for the boiler mounting bracket assembly.
The location should be in an area where the water pipes will
not be subjected to frost conditions. In siting the boiler the
following limitations must be observed.

The boiler may be installed in any room or internal space,
although particular attention is drawn to the requirements of
the current I.E.E. wiring regulations and in Scotland the
electrical provisions of the building regulations applicable in
Scotland, with respect to the installation of the boiler in a
room or internal space containing a bath or shower.

Where a room sealed appliance is installed in a room containing
a bath or shower any electrical switch or appliance control
utilising mains electricity must be situated so that it cannot be
touched by a person using the bath or shower.

The boiler is supplied ready for wall-hung installation. The
rear frame of the appliance has a series of slots for fastening
it to the wall, using screws with metal wall plugs. The fastening
to the wall must provide stable and effective support of the
appliance.

If the appliance is enclosed in a cabinet or alongside another
appliance, space must be allowed for normal maintenance
operations. Fig. 2 shows the minimum and recommended
space to be left free around the appliance.

WARNING!! This appliance must be installed in a
room with sufficient ventilation, to avoid dangerous
conditions arising in the event of, even minor, gas
leaks. These safety standards are imposed by the
EEC Directive no. 09/396 for all gas appliances,
including the so-called sealed appliances.

For further instruction concerning devices
installation in cascade, please refer to the related
paragraph.

Minimum Recommended

5 cm

A
B

5 cm

C 15 cm 20 cm

1,5 cm

D

(from any openable panel)

15 cm
30 cm

> 50 cm

Fig. 2

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Econcept 50 A

2.3 Connection to the hydraulic system

Make the connections to the corresponding couplings, according to the positions indicated in Fig. 3.
The discharge of the safety valve must be

connected to a funnel or collection pipe, to
discarge against a wall approx 300mm from
ground level.

Make the connections to the boiler so as its
internal pipes are not subject to stress.

Note: Caution must be taken to ensure the
discarge pipe cannot cause damage to
persons en property in the event of discharge.

The appliance is not supplied with an
expansion vessel, and therefore such
device must be connected by the
installer. Please note that the
pressure in the system, when cold,
must be between 0.5 and 1 bar.

Water treatment

If water treatment is used Ferroli Limited
recommend only the use of Fernox or Sentinel water treatment products, which must be used in accordance
with the manufacturers instructions. For further information contact:

50 120 145 145 120 50

1 2 3 4 5

1 CH flow
2 DHW flow
3 Gas inlet

4 DHW return
5 CH return
6 Safety valve

6

Fig. 3

Feronx Manufacturing Co. LTD. Sentinel Division
Tandern house, Marlowe way Betz Dearborn LTD
Croydon, surrey, CRO 4YS Widnes, Cheshire WA8 8ND
Tel: [phone] Tel: [phone]

Note:

• If the boiler is installed in an existing system any unsuitable additives must be removed by thorough
cleasing. All systems should be cleansed according to B.S. 7593.

• In hard water areas treatment to prevent lime scale may be necessary.

• It is important that the correct concentration of the water treatment product is maintained in

accordance with the manufacturers instructions.

Water System

Note The boiler is designed for sealed systems only and must NOT be used on open vented systems.

Central Heating

Detailed recommendations are given in BS6798, BS5449, BS6700 and CP342 Part 2. Pipework not forming
part of the useful heating surface should be insulated to prevent any heat losses or possible freezing (i.e. in
roof spaces or ventilated underfloor spaces). Drain taps should be positioned at the lowest point of the
system in accessible locations to permit the whole system to be drained down. The drain taps should be in
accordance with BS2879. Copper tubing to BS2871, Part 1 is recommended for water carrying pipework.
Pipework in horizontal runs should have a gradient where possible to facilitate the removal of air. Ensure that
the boiler heat exchanger is not a natural point for air collection.

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Econcept 50 A

aa

a

aaa

Kit 1KWMH17A

Cylinder not supplied

Make Up Water

Provision must be made for replacing water lost from the sealed system. Reference should be made to
BS6798, for methods of filling and making up sealed systems. There must be no direct connection between
the boiler's central heating system and the mains water supply. The use of mains water to charge and
pressurise the system directly, is conditional upon the Local Water Byelaws. Again any such connection must
be disconnected after use.

Always connect and filling device to the return pipework

DHW calorifier connection(Optional kit 1KWMH17A)

The optional kit 1KWMH17A is available for connection
with an external cylinder. The kit, which includes circulator,
cylinder feeler and hydraulic pipe fittings, has to be mounted
inside the cylinder, according with instruction contained in
the kit itself. Then the connections have to be joined to the
cylinder.

2.4 Connection to the gas system

If necessary the local Gas supplier should be consulted, at
the installation planning stage, in order to establish the
availability of an adequate supply of gas.

An existing service pipe must not be used without prior
consultation with the Local Gas supplier.

A gas meter can only be connected by the Local Gas
supplier, or by a Local Gas suppliers Contractor.

Installation pipes should be fitted in accordance with
BS6891.

Appliance inlet working pressure must be 20mbar MINIMUM, for NG and 37 mbar minimum for LPG.
Pipework from the meter to the boiler must be of an adequate size.
Do not use pipes of a smaller size than the boiler inlet gas connection.
The complete installation must be tested for gas soundness and purged as described in BS6981. All pipework

must be adequately supported. An isolating gas valve should be fitted on the boiler gas inlet. Please wait
10 minutes when lighting from cold before checking gas rate. Gas pressures should be checked after the
boiler has operated for 10 minutes to ensure thermal equilibrium.

Fig. 4

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Econcept 50 A

2.5 Electrical connections

Power supply

The boiler must be connected to a single-phase, 230 Volt-50 Hz power line, with max 3A fuses fitted between
boiler and the line, as well as a double pole switch (ON/OFF) with contacts whose opening is at least 3 mm.
The boiler must always be properly earthed.

When electrically connecting the boiler to an electrical system with live and neutral, THE POLARITY MUST
BE RESPECTED (LIVE: brown wire / NEUTRAL: blue wire / EARTH: yellow-green). Note: If replacing the
electrical power cable, use only the “HAR H05 VV-F” cable, 3x0.75 mm2, with a maximum external diameter
of 8 mm.

Room thermostat, external unit and auxiliary controls

Below the electrical control box is a multipolar
terminal block, for connecting:

• Room thermostat (3-4)
WARNING: THE ROOM THERMOSTAT
MUST NOT HAVE LIVE CONTACTS. CON­NECTING 230V TO TERMINALS (3-4) WILL
CAUSE IRREVERSIBLE DAMAGE TO THE
ELECTRONIC BOARD.
When connecting a room thermostat with
daily or weekly program, or a timer, avoid
taking the power supply to these devices
from their switch contacts. Their power
supply must derive from a direct connec­tion to the mains or using batteries, de­pending on the type of device.
This appliance must use a room thermostat,
for increased comfort and greater energy
savings.

• External temperature probe (7-8)
With the probe (optional) connected, the
boiler works in outside compensation tem­perature mode, depending on the compen­sation curve settled (ref. 1.4). If no probe is
connected, the boiler works in standard
mode and setting of a compensation curve
(parameter 9 of menu) is ignored by the
control system.

• Remote control (9-10), for remote control
and regulation of the boiler, with weekly
chronothermostat and climatic regulation
functions.

• Optional DHW storage probe to be fitted
to 11-12 otherwise leave 10K -1,8K resistors
fitted (removing resistors will create a boiler
malfunction + result in no C. heating or hot
water production .

23456789101112

Fig. 5

A Room thermostat
B Eco/Comfort selection switch
E Remote control
F DHW storage sensor

12

EBA

Fig. 10 a

F

Fig. 6

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Econcept 50 A

Suggested conection for storage cylinder-:

room thermostat

cyl thermostat

X - CH circuit -- MUST be volt free E - Cascade unit option
Y - DHW circuit -- MUST be volt free F - DHW storage sensor
they must NOT be connected to any external power source

Positioning the external probe

The external probe is best installed on a wall
facing north, north-west or which borders
the majority of the main living area. The
probe must never be exposed to the early
morning sun, and, in general and where
possible, must not receive direct sunlight; if
necessary, it should be shielded.

The probe must not in any case be fitted near
windows, doors, ventilation openings, flues,
or sources of heat which may alter the reading.

Note: The maximum length allowed for

the electrical cable connecting the
boiler to the external probe is 50 m.
A common two-lead cable can also
be used.

Econcept 50 A connection block

23456789101012

EF

XY

programmer

LHE

N

N W

230/50 Vac supply

fused @ 3amp.

Fig. 7

H

1/2H

H

Fig. 8

1/2H

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Econcept 50 A

2.6 Flues

Econcept is a type-C boiler with forced draught, the air inlet and the flue gas outlet must be connected to
one of the exhaust–intake systems indicated as follows. Using the tables and the methods of calculation
described, first verify, before installation, that the flues do not exceed the maximum allowed length.

Connection to concentric pipes

The total length in linear metres of the concentric pipes must not exceed the maximum length indicated in
the first table below. The second table shows the reductions to be used for any bends in the pipes, excluding
the initial one.

Maximum allowable pipe length

Ø125/80 mm concentric

Econcept 50 A

Reducers for concentric bends

90° concentric bend
45° concentric bend

Vertical

4 m

0,5 m

0,25 m

Horizontal*

4 m

Fig. 9

Please consider that the horizontal concentric piping
to allow the condensation which forms in the flues to flow back to the boiler, and avoid external dripping.
The concentric pipes should be sealed with the relative pipe coupling seal at the points of coupling to the
wall. The external piping must protrude from the wall between 10 and 60 mm.

must have a slope towards the boiler of at least 3 mm/m

14

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Two pipe flue system

The separate Ø80 pipes for air intake and flue gas exhaust can be connected directly to the boiler, as shown
in Fig. 10.

Upon request, a wide range of pipes, bends and accessories can be supplied. For the various components,
refer to tables 1-2 or to the flue accessory catalogue.

A simple calculation can be performed to ensure that the maximum allowable pipe length is not exceeded:

1 For each component, table 1-2 lists the loss of pressure in “equivalent air-metres”, depending on

the position of installation of the component itself (air intake or flue gas exhaust, vertical or
horizontal).

The loss is called “equivalent length” as it relates to the loss of length in the flue system due to
fuctional losses of bends. For example, a 90° Ø80 bend in flue gas exhaust has a loss equivalent to

2.5 air-metres, that is equal to 2.5 linear metres of flue pipe.

2 Once having completely defined the layout of the double flue system, add the losses in equivalent-

metres, according to the position of installation of all the components and accessories in the system

3 Check that the total loss calculated is less than or equal to 45 m equivalent metres, that is the

maximum allowable for this model of boiler.

Fig. 10

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Table of losses for piping and accessories

Econcept 50 A

Horizontal

Tab. 2

Airwall

terminal

products

combustion

Air

protection Ø80 mm

Outlet flue air inlet

for connection with

split end Ø80 mm

Ø80

t

erminal of

Description

of

mm

inlet

Tab. 1

Reduction

Accessories Ø 80 Accessories Ø 80

Description

Tubo Ø 80

male-female

Male-female

bend 90° Ø 80 mm

Condensate flue

outlet

KWMA38A • 0,50 m
KWMA83A • 1,00 m

KWMA82A

Air Flue

Vertical

Horizontal

0,510,510,8

1,5 2,0

1,612

Vertical

KWMA86A

KWMA85A

KWMA84U

Reduction

Air Flue

Vertical

Horizontal

Vertical

2

12

Horizontal

5

KWMA55U

3

The loss values listed refer to original FERROLI
pipes and accessories

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Econcept 50 A

Example of how to calculate the connection of two separate pipes, max flue length: 45 metres
The flue and air pipes must be sloped towards the boiler by at least 3%.

3

12 m

12

Ref.

1

2

3

N° Pieces

12

12

1

Fig. 11

Description

Vertical air pipe

Vertical flue pipe

Flue terminal

Length

o loss

19,2 m

12,0 m

12,0 m

43,2 mTotal

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Econcept 50 A

Terminal Position

Minimum dimensions of flue terminal positions

Dimensions Terminal position

a

A

a

B

a

C

D 75 mm
E 200 mm
F 200 mm
G 150 mm
H 300 mm
I 300 mm
J 600 mm

K 1200 mm
L 1200 mm

M 1500 mm
N 300 mm
O N/A
P N/A

Q

l

F

J

L

B

G

A

(kW input expressed in net)

Directly below an opening, air brick, (0-7 kW)
opening windows, etc. (>7-14 kW)

Above an opening, air brick, (0-7 kW)
opening windows, etc. (>7-14 kW)

Horizontally to an opening, air brick, (0-7 kW)
opening windows, etc. (>7-14 kW)

Below gutters, soil pipes or drain pipes
Below eaves
Below balconies or car port roof
From a vertical drain pipe or soil pipe
From an internal or external corner
Above ground roof or balcony level
From a surface facing the terminal

(also see 6.1.2)
From a terminal facing the terminal
From an opening in the car port ( e.g. door,

window) into the dwelling
Vertically from a terminal on the same wall
Horizontally from a terminal on the same wall
From the wall on which the terminal is mounted
From a vertical structure on the roof

(>14-32 kW)
(>32-70 kW)

(>14-32 kW)
(>32-70 kW)

(>14-32 kW)
(>32-70 kW)

Q

C

Fig. 12

D, E

P

Q

N

MM

H

H

N

Balanced flues room

sealed
Fanned

draught

300 mm

300 mm

300 mm

b

K

Q N/A

NOTE N/A = Not applicable

a

I

n addition, the terminal should not be nearer than 150 mm (fanned draucht) or 300 mm (natural draught) to an opening in the building fabric
formed for the purpose of accommodating a built-in element such as a window frame, (see Figure C2). Separation distances are linked to the
rated heat inputs as shown.

Above intersection with roof

18

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Econcept 50 A

2.7 Condensation discharge connection

Boiler is provided with an internal watertrap for
the condensation discharge. Fit the inspection
bowl "A" and the flexible tube "B". Fill the
siphon with 0,5 l. of water and connect the
flexible tube to the draining system. If this is not
possible the trap will fill upon the boiler running
for approx 20 mins, (care should be taken not to
brear any fumis in discharged from the condense
hose due to insufficient water being present in
the trap).

Fig. 13

Connect to internal waste system or soakaway.
Using plastic not copper.

Fig. 14

19

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Econcept 50 A

2.8 Modular installation

Can be used as a single unit or for modular installation. If the output required from the system exceeds 44,9
kW, two or more Econcept 50 boilers can be connected in a modular system (or cascade), as shown as an
example in figure.

L1 max = 1000 mm
L2 max = 3000 mm

Fig. 15

It is necessary to meet all the requirements imposed by standards and laws in force applicable to this
generator “equivalent” of total potentiality N x 44.9 kW.

Ventilation required via 80mm Ferroli piping (see page 16).

For connection in cascade, please observe the following instruction:

Hydraulic connection

• Connect all units to a double collector hydraulic circuit (one collector for flow one for return) or single-pipe,
utilising isolation valves which permit the isolation at each boiler in case of maintenance. Distance between
module and module (D1) must be lower than 0.5 metres.

• Provide safety and protection device prescribed by standards in force for modular boilers complete of N
x 44.9 kW capacity. They must be installed on the flow circuit pipe, immediately below last module, within
a distance not higher than 0.5 metres.

20

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Econcept 50 A

• It is emphasized that every Econcept 50 module is equipped with all its own necessary and/or compulsory
safety devices. In particular, every Econcept 50 device is equipped with its own safety valve against
overpressure (3bar), low water pressure switch, safety stat, limit stat. In case of overheating, absence of
water or absence of circulation into the boiler, safety devices cause the switch-off or the locking out of
boiler, preventing its running.

Cascade control system and electric connections

• Use the electronic control box sequence 1KWMH18A (optional) for the automatic management of cascade
devices. Every control box allow the management from 2 to 5 Econcept boilers in cascade. More control
boxes can be connected one to another in parallel to allow further expansions (10, 15, 20 … Econcept 50
boilers in cascade). For electric connections, see the instruction provided in the kit.

Flue Evacuation

• The collector, the flue and the chimney must be correctly sized, designed and built to the standards in
force. They must be made of appropriate material for the purpose, that means resistant to high
temperatures and corrosion, smooth inside and hermetically sealed. In particular, connections must be
condensation-tight. Furthermore, provide suitable condensation drainage points, connected to a trap.

• Connect the flue outlet (Ø 80) of single modules, as shown in figure, is being careful to respect diameters
of collectors and chimneys written in the table below.

N°

Econcept 50 AØcollector/chimney

2
3
4
5
6
7
8
9

10

• Air intake can take place in the boiler room, on condition that the room is properly ventilated according
to the standards in force. Be careful to remove air blanking plus from every single module.

150
180
200
250
250
300
300
350
350

Fig. 15a

21

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Econcept 50 A

3. SERVICE AND MAINTENANCE

3.1 Settings

The adjustment of the software operations must only be performed by Qualified Personnel.
FERROLI S.p.A. declines all liability for damage to persons and/or things deriving from tampering with the

appliance by non-authorised persons.

Gas conversion

A conversion kit is required:

1 Remove jacket.
2 Open sealed room department.
3 Release "A" connection.
4 Change the injector using the one in the kit.
5 Re-tighten "A" and check that there are no gas

losses.

6 Once the regulation has been made, apply the

data plate contained in the conversion kit next to
the data plate and reassemble the boiler casing
and the lower protection plate.

7 Run the boiler.
8 Re-set the CO2 the specified measurament of

9,5% +/- 0,1% at max output.

A

Test mode

Press " " and " " keys together for 3 seconds
to enter mode.

Catagorie

2E

Fuel type Ø
(G20) 6,70 mm

(G31) 4,75 mm3P

Fig. 16

22

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Econcept 50 A

Boiler parameters regulation

Pressing " - mode" button and " " button simultaneously for more than 3 seconds it allows entry to
the boiler parameters menu.

Then pressing " " button it is possible to scroll the parameters, while with " " and " " buttons it is
possible to modify values set.

It is necessary to press " - confirm" button to set new values.

Temperatures regulation

Pressing " - mode" button it is possible to enter the user menu (see par. 1 for a complete description)
where it is possible to modify:

Par. “1” • CH temperature

Set
value
70°C

Par. “2” • DHW temperature

Set
value
50°C

Regulations over described can be made only if remote control is not connected.

The boiler is equipped with a safety device that temporarily stops the running in case of too high ∆t.

Adjustable from
30 to 90°C

Adjustable from
40 to 65°C

3.2 Commissioning and testing

The appliance must only be set-up for use by Qualified Personnel, such as personnel from Technical
organization.

Checks to be performed during the first ignition, and after all maintenance operations which may have
required the disconnection of the systems or intervention on the safety devices or parts of the boiler:

Before igniting the boiler:

• Open any shut-off valves between the boiler and the systems

• Check the seal of the gas system, proceeding with care and using a leak detection solution to find any leaks

from the connections.

• Fill the system as indicated earlier and ensure that the air contained in the boiler and the system has been
completely vented, by opening the air bleeding valve on the top of the appliance (Fig. 2) and any bleeding
valves in the system.

• Check that there are no water leaks in the heating system, in the domestic hot water circuits, in the
connections or in the boiler

• Check the correct connection of the electrical system

• Check that the appliance is properly earthed;.

• Check the correct connection of the appliance to the system for draining the condensation and the

functioning of the condensation drain system itself.

• Check that the pressure value and gas rate for the heating system are correct.

• Check that there are no flammable liquids or materials in the immediate vicinity of the boiler

23

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Econcept 50 A

Igniting the boiler:

• Open the gas control valve upstream from the boiler.

• Purge the gas supply.

• Ensure electrical controls are calling for heat.

• Place the main switch in the ON position.

• The boiler will switch on and perform a complete self-test cycle lasting around one minute, to check the

operation of the main parts. The display shows, in sequence:

Software version
Parameter version

Operation in test -

• If the cycle is performed correctly:

- If domestic hot water or heating is not required, the display shows a small “ “ (standby mode) followed
by the temperature value of the C.H. outlet sensor. Then use the room thermostat or remote control
to activate the request for heating

- If there is a request, the display will pass from the standby phase “ “ to the heating phase “ c “ and
the boiler will automatically begin operation, controlled by its regulation and safety devices.

- If anomalies arise during the self-test cycle or the successive ignition phase, the display will show the
corresponding error code and the boiler will shut-down. Wait around 15 seconds and then press the
reset button. The boiler will repeat the ignition cycle. If, after a second attempt, the boiler does not start,
refer to the paragraph on “Troubleshooting” 3.4.

Note In the case of power failures while the boiler is in operation, the burner assembly will switch off. On

the return of mains power, the boiler will again perform the self-test cycle, following which the burner
assembly will automatically restart (if there is still a request for heat).

Checks during operation

• Ensure there are no gas or water leaks.

• Check the efficiency of the flues and air-flue gas pipes during the operation of the boiler.

• Check that the water circulation between the boiler and the systems is correct.

• Ensure that the gas valve modulates correctly.

• Check the correct ignition of the boiler, effecting a series of ignition and shut-down tests using the room

thermostat or the remote control.

• Ensure that the gas rate at the meter is correct as giving in table at pag. 30.

• Check the correct setting of the parameters and effect any custom settings required (compensation curve,

heat rates, temperatures, etc.)

Shut-down

Close the gas control valve upstream from the boiler and disconnect the electrical power supply to the
appliance.

Warning - For long periods of inactivity during the winter months, in order to avoid damage due to freezing,
all the water should be drained from the boiler, both the domestic hot water and the heating system;
alternatively, drain only the domestic hot water and introduce the relative antifreeze into the heating system.

24

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Econcept 50 A

3.3 Maintenance

The following operations must only be performed by Qualified Personnel, such as personnel from Ferroli
Limited UK.

Seasonal checks on the boiler and the flue

The following checks should be made on the appliance at least once a year:

• The control and safety devices (gas valve, thermostats, etc.) must be working properly.

• The pipes and the air-flue gas terminals must be free of obstacles and not contain any leaks.

• The condensation draining system must be efficient and must not contain any leaks or blockages

• The gas and water systems must be perfectly sealed.

• The burner assembly and the heat exchanger must be clean. Follow the instructions in the next paragraph.

• The electrodes must be free of deposits and positioned correctly.

• The pressure of the water system when cold must be around 1 – 1.5 bar; if not, top up system.

• The expansion vessel must be presurised.

• The circulation and domestic hot water pumps must be free to run.

Cleaning the boiler body and the burner assembly

The burner assembly and the parts of the boiler body in contact with condensation should be cleaned once
a year. To clean these parts, use soft brushes or compressed air; do not use chemical products or steel
brushes.

After these checks, ensure there are no escape of gas.

25

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Econcept 50 A

3.4 Troubleshooting

Diagnostics

The boiler features an advanced self-diagnostic system. In the case of an fault in operation, the display flashes
and the code identifying the fault appears. The faults marked with the letter “A” cause the permanent shut­down of the boiler. To reset operation the boiler must be restarted manually, pressing the “R” (reset) button.

The faults marked by the letter “F” cause temporary shut-down and are reset automatically as soon as the
value returns within the boiler’s normal operating range.

The following table lists a number of indications for resolving the faults signalled by the boiler. Adjustmens
on the appliance must only be carried out by Qualified Personnel, such as the personnel from the FERROLI
Customer Technical Service Centre. For any operations on the appliance or which require the opening of the
boiler, always request the assistance of the service centre.

Fault Possible cause Solution

Failed burner
assembly ignition

Safety thermostat
activation

Flue safety device
intervention

No flame following the
ignition phase

• No gas

• Ignition or detection

electrode fault

• Defective gas valve

• Faulty full auto control

• Outlet sensor not active

• No system circulation

• Flue partially blocked

or insufficient

• Low gas pressure

• Faulty ionisation probe

• Faulty full auto control

• Check that the gas flow to the boiler

is correct and that air has been
purged from the piping

• Check the wiring to the electrodes
and that these are positioned
correctly and free of deposits

• Check and replace the gas valve
if required

• Check the correct positioning and
operation of the outlet sensor

• Check the pump

• Check the efficiency of the flue,

the flue gas exhaust pipes and
the outlet terminal

• Check as necessary

Insufficient water system
pressure

Fan fault • Fan not powered

• System empty • Fill the system to 1.5 bar

• Defective fan

26

• Check the wiring to
the fan

• Replace the fan

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Econcept 50 A

Fault Possible cause Solution

High flue gas temperature
3 x

Excessive central heating
outlet temperature

Excessive central heating
return temperature

Outlet sensor faulty • Sensor damaged or

Return sensor faulty • Sensor damaged or

Domestic hot water sensor
faulty

in 24 hours =

• Flue partially blocked
or insufficient sized

• Pump blocked

• Pump faulty

• No system circulation • Check system and pump

wiring cut

wiring cut

• Sensor damaged or
wiring cut

• Check the efficiency of the flue,
the flue gas exhaust pipes and
the outlet terminal

• Free the pump by removing the
cap and rotating the shaft with a
screwdriver

• Check or replace the condenser
or the pump

• Check wiring or replace the
sensor

• Check wiring or replace the
sensor

• Check wiring or replace the
sensor

Flue gas sensor faulty • Sensor damaged or

wiring cut

External probe faulty
(if installed)

No communication between
main board and ignition devices

Microprocessor faulty • Microprocessor operation

• Sensor damaged or
wiring short-circuited

• Wiring cut or incorrect
between main board and
ignition devices

faulty

• Check wiring or replace the
sensor

• Check wiring or replace the
sensor

• Check the wiring and the
connections between the
boards

• Disconnect and restore the
electrical power supply. If the
problem persists check and/or
replace the main board

27

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Econcept 50 A

4. TECHNICAL CHARACTERISTICS AND DATA

4.1 Dimensions and connections

Key

1 Gas inlet
2 C. H. flow
3 C. H. return

Fig. 17

28

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ECONCEPT 50 A

4.2 General view and main components

OUT AIR VENT

Fig. 18

Key

16 Fan
32 Central heating pump
34 C.h. flow temperature sensor
44 Combination gas valve
49 Overheat cut-off thermostat
68 Control box with p.c.b.
82 Ionisation electrode
83 Full sequence automatic control
98 Switch

101 Main p.c.b.
114 Low water pressure switch
117 Opening solenoid valve for gas (max 20W)
186 Return temperature sensor
188 Hot surface igniter
191 Exhaust temperature sensor
202 Trasformer 230v-24v
204 PC connector
207 Boiler connector

29

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4.3 Technical data table

Econcept 50 A

Output

Heat rate Hi (input)
Useful heat output 80°C - 60°C
Useful heat output 50°C - 30°C

Gas supply

Gas Injector G20
Supply pressure G20
Natural gas rate (G20)
Gas Injector G31
Supply pressure G31
LPG gas rate (G31)
Air Injector

Heating

Maximum operating pressure
Boiler total water content

Dimensions, weights connections

Height
Width
Depth
Weight with packaging
Gas system fittings
Heating system delivery
Heating system return

Power supply

Max electrical power absorbed
Power supply voltage/frequency
Index of protection

kW
kW
kW

mm
mbar

3

nm

/h
mm
mbar
kg/h
mm Ø

bar
litres

mm
mm
mm
kg
Inches
Inches
Inches

W
V/Hz
IP

Pmax Pmin

46,0 13,8
45,2 13,6
48,4 14,4

6,70
20,0

4,86 1,46

4,75
37,0

3,6 1,8

23,5

3

2,7

720
630
280

51

3/4”

1”
1”

190

230/50

X4D

30

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ECONCEPT 50 A

4.4 Diagrams

6

5

4

3

mt.ca

P

3

2

1

2

1

0

0 0,5 1 1,5 2 2,5 3 3,5 4

mc/h

Fig. 19

31

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4.5 Wiring diagrams

Econcept 50 A

Fig. 20

Key

16 Fan
32 Central heating pump
34 C.h. flow temperature sensor
44 Combination gas valve
49 Overheat cut-off thermostat
72 Room thermostat (not fitted)
82 Ionisation electrode
83 Full sequence automatic control
98 Switch
101 Main p.c.b.
104 Fuse
114 Water pressure switch
117 Opening solenoid valve for gas (max 20W)

130 D.h.w. pump
138 Outside temperature sensor
139 Room unit
155 Storage tank senser
186 Return temperature sensor
188 Hot surface igniter
191 Exhaust temperature sensor
202 Transformer 230v-24v
203 230v
204 PC connector
207 Boiler connector

32

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Should you require help with any difficulties

call our Technical Service Helpline on

08707 282 885

Phone numbers:

Installer

Service Engineer

BECAUSE OF OUR CONSTANT ENDEAVOUR FOR IMPROVEMENT DETAILS
MAY VARY SLIGHTLY FROM THOSE QUOTED IN THESE INSTRUCTIONS.

ALL SPECIFICATIONS SUBJECT TO CHANGE

Please note - to avoid incurring unnecessary expense, in the event of a boiler shut down, check this in

not caused by lack of electricity supply, gas supply or low water pressure before calling our Customer

Service Helpline.

Lichfield Road, Branston Industrial Estate, Burton Upon Trent, Staffordshire DE14 3HD

Tel. [phone] - Fax [phone]