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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