Ferroli ECONCEPT 51, ECONCEPT 51i, ECONCEPT 101, ECONCEPT 101i Instructions For Use, Installation And Maintenance

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cod. 3540S572 — 11/2010 (Rev. 00)

ECONCEPT 51 - 101
ECONCEPT 51i - 101i

ISTRUZIONE PER L’USO L'INSTALLAZIONE E LA MANUTENZIONE
INSTRUCCIONES DE USO, INSTALACIÓN Y MANTENIMIENTO

KULLANMA, KURULUM VE BAKøM TALIMATLAR

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INSTRUCTIONS FOR USE, INSTALLATION AND MAINTENANCE
INSTRUCTIONS D'UTILISATION, D'INSTALLATION ET D'ENTRETIEN

INSTRUCğIUNI DE UTILIZARE, INSTALARE ùI ÎNTRETINERE

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ECONCEPT 51/51i - 101/101i

47

EN

cod. 3540S572 - 11/2010 (Rev. 00)

EN

1. GENERAL INSTRUCTIONS

• Carefully read the instructions contained in this instruction booklet.

• After boiler installation, inform the user regarding its operation and give him this manual, which 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.

2. OPERATING INSTRUCTIONS

2.1 Introduction

Dear Customer,
Thank you for choosing ECONCEPT 51/51i - 101/101i, heat generator of the latest gen-

eration FERROLIfeaturing advanced design and cutting-edge technology. Please read
this manual carefully since it provides important information on safe installation, use and
maintenance.

ECONCEPT 51/51i - 101/101i is a high-efficiency modular premix condensing heat
generator for heating with very low emissions, running on natural gas or LPG and ar­ranged for installation in cascade.

Each ECONCEPT 51/51i - 101/101i module is equipped with a double aluminium lamel­lar exchanger and double ceramic premix burner housed in a vertical cabinet in AISI 316
stainless steel (version ECONCEPT 51i - 101i) or in epoxy powder coated steel resistant
to atmospheric agents (version ECONCEPT 51 - 101).

The plumbing circuits of the exchangers, each equipped with its own local circulating
pump, run into system delivery and return manifolds inside the module. The control sys­tem has a microprocessor and user interface with a large display.

A cascade control unit, available by request, enables effective and economical manage­ment of the modules ECONCEPT 51/51i - 101/101i connected in cascade.

The generators ECONCEPT 51/51i - 101/101i are designed for installation even outside.
The versions ECONCEPT 51i - 101i with stainless steel cabinet are particularly recom­mended for places where the climatic and environmental conditions are unfavourable.

2.2 Control panel

fig. 1 - Control panel

The control panel is located inside the cabinet. To access it, open the front door with the
special key supplied.

Key
1 = DHW temperature setting decrease button (with optional hot water tank in-

stalled)

2 = DHW temperature setting increase button (with optional hot water tank in-

stalled)

3 = Heating system temperature setting decrease button
4 = Heating system temperature setting increase button
5 = Display
6 = Summer/Winter mode selection button
7 = Economy/Comfort mode selection (with optional hot water tank installed) and

unit On/Off button

8 = Reset button
9 = DHW operation (with optional hot water tank installed)
10 = Summer mode
11 = Multifunction

12 = Eco (Economy) mode (with optional hot water tank installed)
13 = Heating mode
14 = Unit On / Off button
15 = Burner On
16 = Appears on connecting the Remote Timer Control (optional)
17 = Information symbol
18 = Top boiler shell
19 = Top boiler shell system fault reset request
20 = Fault
21 = Circulating pump On
22 = Appears on connecting the external probe (optional)
23 = Boiler Off
24 = Bottom boiler shell
25 = Bottom boiler shell system fault reset request (model ECONCEPT 101/

101ionly)

Indication during operation

Heating

A heating demand (generated by the Room Thermostat or Remote Timer Control or 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
heating standby time, the message "d". Activation of the arrows (details 18 and 24 ­fig. 1) indicates which boiler shell is on.

fig. 2

DHW (with optional hot water tank installed)

A hot water tank heating demand is indicated by activation of the circulating pump and
the tap (details 9 and 21 - fig. 1). The display (detail 11 - fig. 1) shows the actual hot water
tank sensor temperature and, during heating standby time, the message "d". Activation
of the arrows (details 18 and 24 - fig. 1) indicates which boiler shell is on.

fig. 3 -

Exclude hot water storage 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 eco/comfort button (detail 7 - fig. 1). In ECO mode
the display activates the symbol (detail 12 - fig. 1). To activate the COMFORT
mode, press the eco/comfort button (detail 7 - fig. 1) again.

2.3 Lighting and turning off

Boiler lighting

Press the On/Off button (detail 14 fig. 1).

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 software version of the
cards:

A = Display card software version
B = Top boiler shell control unit software version
C = Bottom boiler shell control unit software version (model ECONCEPT 101/
101ionly)

• Open the gas cock ahead of the boiler.

• When the message FH disappears, the boiler is ready to operate automatically in
case of a room thermostat demand.

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ECONCEPT 51/51i - 101/101i

48

EN

cod. 3540S572 - 11/2010 (Rev. 00)

Turning the boiler off

Press the button (detail 7 - fig. 1) for 5 seconds.

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 dis-

abled. The antifreeze system remains activated.
To relight the boiler, press the button (detail 7 fig. 1) again for 5 seconds.

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.

B

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.

2.4 Adjustments

Summer/Winter Switchover

Press the button detail 6 - fig. 1 for 1 second.

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 (detail 6 - fig. 1) again for 1 sec­ond.

Heating temperature adjustment

Use the heating buttons (details 3 and 4 - fig. 1) to adjust the tempera­ture from a min. of 20°C to a max. of 90°C.

fig. 8

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 10°C to a max. of 65°C.

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

When the optional external probe is installed the corresponding symbol (detailfig. 122 ­) is activated on the control panel display (detail 5 - fig. 1). The boiler control system op­erates with "Sliding Temperature". In this mode, the heating system temperature is ad­justed according to the outside weather conditions, to ensure high comfort and energy
saving throughout the year. In particular, as the outside temperature increases, the sys­tem delivery temperature is decreased 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 regulated at the time of installation by qualified personnel. Adjust­ments can in any case be made by the user to improve comfort .

Compensation curve and curve offset
Press the button (detail 8 - fig. 1) for 5 seconds, to display the actual com-

pensation curve (fig. 10) which can be modified with the DHW buttons
(details 1 and 2 - fig. 1).

Adjust the required curve from 1 to 10 according to the characteristic (fig. 12).
By setting the curve to 0, sliding temperature adjustment is disabled.

fig. 10 - Compensation curve

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

- fig. 1).

fig. 11 - Curve parallel offset

Press the button (detail 8 - fig. 1) again for 5 seconds to exit parallel curve
adjustment mode.

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.

fig. 12 - Compensation curves

fig. 13 - Example of compensation parallel curve offset

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ECONCEPT 51/51i - 101/101i

49

EN

cod. 3540S572 - 11/2010 (Rev. 00)

A

If the Remote Timer Control (optional) is connected to the boiler, the above ad­justments are managed according to that given in table 1.

Table. 1

System water pressure adjustment

The filling pressure with the system cold must be approx. 1.0 bar. If the system pressure
falls to values below minimum, the boiler card will activate fault F37 (fig. 14). Flashing of
the arrows (details 18 and 24 - fig. 1) together with the error code indicates which boiler
shell is in fault status.

fig. 14 - Low system pressure fault

A

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 51/51i - 101/101i is a high-efficiency heat generator arranged to operate
alone or in cascade (bank). When two or more generators ECONCEPT 51/51i - 101/101i
are installed in cascade with the original kits FERROLI, respecting the prescriptions of
this manual, they can be considered as a single heat generator of total power equal to
the sum of the powers of all the units connected in cascade.

All the requirements of the current standards and regulations applicable to this “equiva­lent” generator with total heating capacity must be met. In particular the place of instal­lation, safety devices and fume exhaust system must be adequate for the total heating
capacity of the bank of units.

In fact, each ECONCEPT 51/51i - 101/101i is a complete and independent heat 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 generator can be installed directly outside or in a suitable room with ventilation open­ings to the outside as prescribed by the current regulations. If there are several burners
or extraction units that can work together in the same room, the ventilation openings
must be sized for simultaneous operation of all the units. The place of installation must
be free of flammable objects or materials, corrosive gases, volatile substances or dusts.
For positioning, leave enough space around the modules for normal maintenance oper­ations. Make sure the front door opens without hindrance.

B

The air necessary for combustion enters through special openings in the bot­tom and top part of the unit. Make sure these air passages are not obstructed
in any way.

fig. 15 - Air inlet

3.3 Gas and water connections

Plumbing connections

Make the relevant connections according to the instructions given below. Make the gen­erator connection in such a way that its internal pipes are free of stress. For proper op­eration and long life of the generator, the plumbing system must be of suitable size and
complete with all the accessories that guarantee regular operation and running.

In particular, provide for all the protection and safety devices prescribed by current reg­ulations for the complete modular generator. They must be installed on the hot water cir­cuit delivery piping, immediately downstream of the last module, within a distance of 0.5
m, with no shut-off devices in between. A "Safety Device and Circuit Breaker module”
equipped with internal hydraulic circuit breaker and safety units with ISPESL certification
is available by request. Refer to the price-list or contact our sales network. The unit is not
supplied with an expansion tank; its connection must therefore be made by the Installer.

B

A filter must also be installed on the system return piping to prevent impurities
or sludge from the system clogging and damaging the heat generators.

The filter must necessarily be installed when replacing generators in existing
systems. The manufacturer declines any liability for damage caused to the gen­erator by failure to install or inadequate installation of this filter.

Water system characteristics

In the presence of water harder than 25° Fr, it is advisable to use suitably treated water,
in order to avoid possible scaling in the boiler caused by hard water, or corrosion pro­duced by aggressive water. Due to its low thermal conductivity, scaling even just a few
mm thick causes significant overheating of the generator walls, with consequent serious
problems.

Water treatment is indispensable in case of very large systems (containing large
amounts of water) or with frequent introduction of replenishing water in the system. If par­tial or total emptying of the system becomes necessary in these cases, it is advisable to
refill with treated water.

Gas connection

The gas must be connected to the corresponding union with a rigid metal pipe.
The gas meter must be adequate for the simultaneous use of all units connected to it.

Carry out the generator gas connection in accordance with current regulations. The di­ameter of the gas pipe leaving the generator does not determine the diameter of the pipe
between the unit and the meter; it must be chosen according to its length and pressure
loss.

B

Make sure to install a fuel shutoff valve externally with respect to the modules,
enabling the gas to be turned off even without opening the single modules
equipped with key closing.

Connection instructions
ECONCEPT 51/51i - 101/101i is equipped inside with 3 manifolds (gas, system delivery

and return) and a condensate drain pipe that facilitate cascade connection and also con­nection of a single module to the system. The manifolds are sized for connecting up to 5
modules in series. The cabinet contains a set of flanges, seals and screws for the con­nection.

To connect a single module - fig. 16

• After determining on which side of the module to make the water and gas connec-

tions, connect the flanges with the joining section contained in the kit on that side
after suitably welding them to the system pipes. Make sure to correctly to fit the
seals contained in the kit.

• Connect a Ø40 pipe to the condensate drain pipe for removing the condensate pro-

duced during operation (see fig. 37).

• Fit the blind flanges contained in the kit on the opposite side of the module, inserting

the special seals.

To connect several modules in cascade - fig. 17

• Connect the first module to the system and gas pipes, as described above, but with-

out fitting the blind flanges on the opposite side to that of the connection.

• Place the second module on this side, making sure to align the connection flanges

and the condensate drain pipe. Insert the seals contained in the kit between the
flanges of the two modules.

• Fit the bolts contained in the kit on the flanges from inside the first module, making

them come out of the flanges inside the second module. Partially tighten the nuts on
the bolts from inside the second module.

• Before tightening the nuts, make sure all the seals are correctly positioned and join

the condensate drain pipes of the two modules (see fig. 38).

• Tighten the nuts and repeat the connection operations for the following modules

(max.5).

If using a water trap

• At the end, fit the blind flanges on the last module, inserting the special seals (fig. 16

and fig. 17).

If using a direct pump

• Connect the delivery to the return on the last module (see fig. 18).

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)

Adjustment can be made from the Remote Timer Control menu and the boiler control
panel.

Summer/Winter Switchover

Summer mode has priority over a possible Remote Timer Control heating demand.

Eco/Comfort selection

(with optional

hot water tank installed)

On disabling DHW from the Remote Timer Control menu, the boiler selects the Econ­omy mode. In this condition, the button

fig. 1

detail 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.

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ECONCEPT 51/51i - 101/101i

50

EN

cod. 3540S572 - 11/2010 (Rev. 00)

Plumbing connection using one generator with water trap

fig. 16

1 Gas inlet
2 System delivery
3 System return
4 Condensate drain
5 Blind flanges
6 Connection side
7 Flanges with joining section

Plumbing connection using two or more generators with hydraulic separator

fig. 17

1 Gas inlet
2 System delivery
3 System return
4 Condensate drain
5 Blind flanges
6 Connection side
7 Flanges with joining section
8 Seals

Plumbing connection using one or more generators with direct pump

fig. 18

1 Gas inlet
2 System delivery
3 System return
4 Condensate drain
5 Blind flanges
6 Connection side
7 Flanges with joining section
8 Seals
9 Delivery/return connection

Water circuit examples

Key of examples

I ISPESL safety devices
D Hydraulic separator
42 DHW temperature sensor (not supplied)
72 Room thermostat (not supplied)
72b Room thermostat (not supplied)
95 3-way valve - with spring return: at rest on DHW side (not supplied)
130 Hot water tank circulating pump (not supplied)
138 External probe (not supplied)
139 Remote control (not supplied)
298 Cascade temperature sensor (not supplied)
306 Heating system circulating pump (not supplied)
307 Heating system second circulating pump (not supplied)
SM Delivery probe (supplied with kit FZ4)
TS Safety thermostat (not supplied)
PZ Zone pump (not supplied)
FZ4 Zone regulator

Parameters
Each system requires a different parametrisation.Follow the procedure for accessing the

two menus, given below; for the parameters to be modified, refer to the tables given next
to the plumbing diagrams.

"Service Menu"
Press the Reset button for 10 seconds to access the card Service Menu.
Press the Heating buttons to select "tS", "In", "Hi" or "rE"”. “tS” means Transparent Pa-

rameters Menu, “In” Information Menu, “Hi” History Menu, and “rE” History Menu Reset.
Select "tS" and press the Reset button.

The card has 29 transparent parameters also modifiable from Remote Control (Service
Menu).

Press the Heating buttons to scroll the list of parameters in increasing or decreasing 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 the card Service Menu.

"System Type Menu"
Press the Summer/Winter button for 10 seconds to access the card System Type Menu.
The card has 21 transparent parameters.
Press the Heating buttons to scroll the list of parameters in increasing or decreasing or-

der. Press the DHW buttons to modify the value of a parameter: the change will be au­tomatically saved.

Press the Summer/Winter button for 10 seconds to exit the card System Type Menu.
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.

fig. 19

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.

fig. 20

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ECONCEPT 51/51i - 101/101i

51

EN

cod. 3540S572 - 11/2010 (Rev. 00)

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.

fig. 21

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.

fig. 22

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 reg-

ulator" handbook

fig. 23

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 reg-

ulator" handbook

fig. 24

3.4 Electrical connections

Connection to the electrical grid

B

The unit's electrical safety is only guaranteed when correctly connected to an
efficient earthing system executed according to current safety standards. Have
the efficiency and suitability of the earthing system checked by professionally
qualified personnel. The manufacturer is not responsible for any damage
caused by failure to earth the system. Also make sure that the electrical system
is adequate for the maximum power absorbed by the unit, as specified on the
boiler dataplate.

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

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.

Room thermostat (optional)

B

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.

External probe (optional)

Connect the probe to its respective terminals. The maximum permissible length for the
boiler - external probe connection electrical cable is 50 m. A normal 2-wire cable can be
used. The external probe should preferably be installed on the North, North-West wall or
that facing the largest area of living room. The probe must never be exposed to the early
morning sun or, insofar as possible, direct sunlight; protect it if necessary. In any case,
the probe must not be installed near windows, doors, ventilation openings, flues or heat
sources that could affect the reading.

fig. 25 - External probe positioning not recommended

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