Ferroli ECONCEPT 100 Troubleshooting guide

ECONCEPT 100
premixed gas-fired heat generator
with condensation
INSTRUCTIONS FOR USE, INSTALLATION AND MAINTENANCE

ECONCEPT 100
2
IMPORTANT
Your "benchmark" Installation, Commissioning and Service Record Log Book is enclosed in the
last pages of this manual. “This record must be completed and left with the end user”.
Ferroli is a member of the Benchmark initiative and fully supports the aims of the programme.
Benchmark has been introduced to improve the standards of installation and commissioning of central
heating systems in the UK and to encourage the regular servicing of all central heating systems to
ensure safety and efficiency.
Please see installation and servicing guidelines.
• Read the warnings given in this manual thoroughly.
They provide important information for safe instal-
lation, use and maintenance
• The instruction manual, by law must be left with the
end user.
• If the appliance is sold or transferred to another
owner or if the owner moves, leaving the appliance
behind, always ensure that the manual is kept with
the appliance for consultation by the new owner
and /or installer.
• Incorrect installation or poor maintenance absolves
the manufacturer from all liability for damage to
persons and property.
• Installation and maintenance must be carried out
in accordance with current legislation, according
to the manufacturer’s instructions and by qualified
corgi registered engineer.
• Before service or maintenance work is carried out
isolate the appliance from the mains electricity
supply.
• In the event of malfunction or faulty operation, isolate
the appliance. Do not attempt to repair or carry out
any other operation on the appliance directly. Contact
Ferroli or a qualified engineer only.
• Repairs or the replacement of components must be
carried out exclusively by qualified personnel using
original spare partsonly. Failure toadhere to theabove
may compromise the safety of the appliance.
• To guarantee efficient operation, the appliance must
be serviced once a year by a Corgi registered engi-
neer.
• The appliance may not be used for purposes other
than those for which it was explicitly designed.
• Incorrect installation and use or failure to follow the
instructions provided by the manufacturer absolve
the manufacturer from all liability for damage.
• After unpacking, check that the contents are correct
and undamaged.
• Keep packing out of reach of children as it could be
potentially hazardous.
• To clean external parts, use a damp cloth moistened
with soapy water if necessary. Avoid using abrasive
cleaning products and solvents.
This symbol indicates “Caution” and is placed next to all safety information.
Strictly follow these instructions in order to avoid danger and damage to persons
or property.
This symbols calls attention to a note or important information, please read thou-
rougly.
Declaration of conformity
Manufacturer: FERROLI S.p.A.
Address: Via Ritonda 78/a 37047 San Bonifacio VR Italy
declares that this unit complies with the following EU directives:
• Gas Appliance Directive 90/396
• Efficiency Directive 92/42
• Low Voltage Directive 73/23 (amended by 93/68)
• Electromagnetic Compatibility Directive 89/336 (amended by 93/68)
President and Legal Representative
Cav. del Lavoro
Dante Ferroli

ECONCEPT 100
3
1. OPERATING INSTRUCTIONS .............................................................. 4
1.1 Introduction ................................................................................................. 4
1.2 Control panel ............................................................................................... 5
1.3 External control units................................................................................... 8
1.4 Switching on and off .................................................................................... 9
1.5 Anomalies..................................................................................................... 9
2. INSTALLATION.................................................................................. 10
2.1 General Instructions..................................................................................... 10
2.2 Connection in cascade................................................................................. 10
2.3 Place of installation ...................................................................................... 11
2.4 Gas and water connections ......................................................................... 11
2.5 Electrical Connections ................................................................................. 14
2.6 Flue connection............................................................................................ 16
2.7 Condensate drain......................................................................................... 16
3. SERVICE AND MAINTENANCE......................................................... 17
3.1 Adjustments ................................................................................................. 17
3.2 System start-up............................................................................................ 18
3.3 Maintenance................................................................................................. 20
3.4 Troubleshooting........................................................................................... 21
4 TECHNICAL CHARACTERISTICS AND DATA ..................................... 23
4.1 Dimensions and connections ....................................................................... 23
4.2 General view and main components ........................................................... 24
4.3 Technical data table..................................................................................... 25
4.4 Diagram of circulating pump losses of pressure / head ............................. 26
4.5 Wiring diagram ............................................................................................ 27
BENCHMARK ........................................................................................ 28

4
ECONCEPT 100
1. OPERATING INSTRUCTIONS
1.1 Introduction
Dear Customer,
Thank you for choosing Econcept 100, a FERROLI heat generator of the latest generation featuring ad-
vanced design and cutting-edge technology.
Econcept 100 is a high-efficiency modular heat generator for condensation premixed heating with very
low emissions, running on natural gas or LPG.
Each Econcept 100 module is equipped with a twin aluminium laminar exchanger and a twin ceramic
premixed burner contained in an upright cabinet made of AISI 316 stainless steel.
Each boiler shell (exchanger + burner) is governed by its own microprocessor control system with self-
diagnostics, able to work independently.
The user interface is easy to use with a keypad and display, making it possible to know appliance operating
status at any time. The operating parameters and historical data are stored internally and can be retrieved
via the interface with a Personal Computer to make Service operations easier.
The plumbing circuits of the exchangers, each equipped with its own local circulating pump, run into system
delivery and return manifolds inside the module.
A cascade control unit, available on request, enables effective and economical control of the two internal
boiler shells or several Econcept 100 modules connected in cascade.
Boiler shell
1
Boiler shell
2
Cascade control
unit (on request)
Boiler shell 1 and 2
control panel
Fig. 1

5
ECONCEPT 100
OFFON
OFF
ON
Display D1
boiler 1
Display D2/D3
boiler 1
Boiler 1
ignition button
(switches the top boiler shell on)
Display D1
boiler 2
Display D2/D3
boiler 2
Boiler 2
ignition button
(switches the bottom boiler shell on)
1.2 Control panel
From the control panel it is possible to display appliance operation status and set the operating parameters
of the two heat exchanger + burner shells inside the module.
At the control panel level, operation adjustment and display are entirely independent for the two internal
boiler shells.
Fig. 2
MODE key - Use to scroll the parameters.
RESET key - Use to reset generator operation in case of shutdown.
EDIT keys - Use to edit the settings.
CONFIRM key - Use to enable the setting value.
MODE display - Shows the generator operation mode or the selected parameter.
DATA display - Shows the parameter value
Key functions
Display information

6
ECONCEPT 100
Operating mode
Standby
Heating
Standby after heating op.
Display D1 Display D2/D3
System delivery temperature
System delivery temperature
System delivery temperature
Summer/Winter selection (00 = Summer  11 = Winter)
DO NOT HANGE THIS PARAMETER*
System delivery temperature display and setting
Not used
System return temperature display
Outside temperature display
Not used
Not used
Not used
Boiler power display
ompensation curve display and setting
Not used
DISPLAY D1 DISPLAY D2 - D3
Display of operation details
The display shows appliance status during operation, without pressing any keys:
Accessing the operational menu
Press the “ - mode” key to access the operation menu. Press the “ - mode” key again to display the
following parameters and information in sequence:
*Important: For correct generator operation this parameter must remain set at “00”.

7
ECONCEPT 100
20
30
40
50
60
70
80
90
2010 0 -10 -20
Outside tem
p
erature °
System delivery
temperature °
1
2
3
4
5
6
7
8
9
10
Adjustments
Setting the system temperature
To set the system delivery temperature on the single boiler shell, access the operational menu and press
the key to display parameter 1 - system delivery temperature. On pressing one of the keys, the
display starts flashing and the delivery temperature setpoint is displayed. Set the required value with the
keys. To activate the new setting, press the key. To cancel, do not press and press .
Summer/Winter selection
For the Summer/Winter selection, access the operation menu and press to display the parameter “0.”.
At parameter “0.”, press one of the keys to display the Summer/Winter selection (the parameter “0.”
flashes); by using the same keys it is possible to select Summer mode (set 00) or Winter mode (set 11). To
activate the new setting, press ; to exit without activating the selection, press .
In “Summer” mode (00) heating is off. The antifreeze function stays on.
Sliding Temperature
When the optional external sensor is installed the generator adjustment system works with “Sliding Tem-
perature”. In this mode, the temperature of the heating system is controlled according to the outside
weather conditions, to ensure a high degree of comfort and energy-saving throughout the year. In particular,
as the outside temperature increases the system delivery temperature decreases according to a specific
“compensation curve“.
With the Sliding Temperature adjustment, the temperature set in parameter 1 of the operation menu be-
comes the maximum system delivery temperature. It is advisable to set a maximum value to permit system
adjustment throughout its useful working range.
The generator must be regulated at the time of installation by qualified personnel. Possible adjustments
can in any case be made by the user to improve comfort: in fact the compensation curve can be modified
from the operation menu with the key and scrolling the menu with the key to parameter 9.
The set compensation curve is displayed (see graph below). On pressing one of the keys, the display
starts flashing and the required value can be set with the keys. To activate the new curve, press .
To cancel, do not press the and press .
If the room temperature is lower than the required value, it is advisable to set a higher curve and vice versa.
Proceed by increasing or decreasing in steps of one and check the result in the room.
Compensation curves

8
ECONCEPT 100
61
2
3
4
5
6
HG/SQ-2
Honeywell
ABS78 9101112131415161718
LNLLLN12
3456
-- COMMON --
JP7
043002X0
1.3 External control units
Cascade control unit (code 1KWMH18A)
A cascade control unit enabling advanced management of the two internal boiler shells is available on
request.
One control unit can manage up to 5 internal boiler shells.
Control unit/module combinations are given in the following table.
For the connection and operating instructions, refer to the manual supplied with the control unit.
Fig. 3a
Control unit 0÷10 Vdc (code 043002X0)
A control unit enabling system temperature adjustment of the single boiler shell according to a signal 0÷10
Vdc is available on request. Therefore 2 control units will be necessary for each heat generator. Control
unit/module combinations are given in the following table.
For the connection and operating instructions, refer to the manual supplied with the control unit.
Fig. 3b
No. of
ECONCEPT 100
modules
No. of control
units 0÷10Vdc
12
24
36
48
510
No. of
ECONCEPT 100
modules
No. of cascade
control units
11
21
32
42
52
IMPORTANT
“Sliding temperature” adjustment will not be available using this control unit.

9
ECONCEPT 100
1.4 Switching on and off
Ignition
Check that any external system shut-off valves are open. Open the gas cock ahead of the generators, turn
the main switch ON and press the ignition keys on the control panel. The boiler will run a self-test cycle
of approx. one minute, after which it is ready for operation. The burner switches on and off completely
automatically depending on system heat demands.
Switching off
In case of prolonged idle periods, close the gas cock ahead of the generators and disconnect the power
supply. In this case, also the boiler antifreeze protection, which switches on the burner for system tempera-
tures below 5°C, is deactivated.
Dangers of freezing
The best protection during extremely cold periods is to keep the boiler and users working so that
the entire system is involved. Alternatively, add antifreeze fluid to the system water, in the amount
recommended by the supplier according to the presumed minimum ambient temperature.
1.5 Anomalies
In case of operation problems or anomalies, the control unit of the single boiler shell activates flashing of
the corresponding display (with fault identification code) and a 230Vac output (to which a visual or acoustic
signalling device can be connected. See the electrical connections section).
Faults marked with the letter “F” cause temporary shutdowns that are automatically reset as soon as the
value returns within the generator’s normal working range.
Faults marked with the letter “A” cause a permanent generator shutdown resettable by the user. To restore
operation, press the key (reset).
If the problem persists, or for any other trouble, refer to the “troubleshooting” section in this manual for
further details and, if necessary, request the intervention of Qualified Personnel or the assistance centre.
In case of appliance fault and/or poor operation, switch it off, and do not make any attempt to repair
it or directly intervene. Contact authorized and professionally qualified personnel.

10
ECONCEPT 100
Safety
elements
GAS
DELIVERY
RET RN
Generators connected in this way can be considered a single “equivalent” heat generator with a total power
of N x 90.4 kW. All the requirements of current standards and regulations applicable to this “equivalent”
generator with total heating power of N x 90.4 kW must be met. In particular, the place of installation,
safety devices and fume extraction system must be adequate for the total heating power N x 90.4 of the
bank of Econcept 100 units.
It is pointed out that each Econcept 100 module is in fact a complete independent heat generator, equipped
with its own safety devices. In particular, each Econcept 100 module is equipped with a water pressure switch,
safety thermostat and electronic limiting device. In case of overtemperature, no water or no circulation in
the unit, the protection devices cause the unit to switch off or shut down, preventing its operation.
The installation instructions given in the following paragraphs concern both single modules and cascade
connections.
Fig. 4
2. INSTALLATION
2.1 General Instructions
This appliance must only be used for its intended purpose. This unit is designed to heat water to a tempera-
ture below boiling point at atmospheric pressure and must be connected to a heating system compatible
with its performance, characteristics and heating capacity. Any other use is considered improper.
THE GENERATOR MUST ONLY BE INSTALLED BY QUALIFIED PERSONNEL, IN ACCORDANCE
WITH ALL THE INSTRUCTIONS GIVEN IN THIS TECHNICAL MANUAL, THE PROVISIONS OF CUR-
RENT LAWS, THE PRESCRIPTIONS OF NATIONAL AND LOCAL STANDARDS, AND THE RULES
OF PROPER WORKMANSHIP.
Incorrect installation can cause damage or injury, for which the manufacturer declines any liability.
2.2 Connection in cascade
Econcept 100 is a heat generator designed to operate separately or in cascade. If the heating power re-
quired by the system exceeds 90.4 kW, two or more Econcept 100 generators can be connected in cascade
(max. 5 heat generators), as shown by way of example in the figure.

11
ECONCEPT 100
2.3 Place of installation
The generator can be installed directly outside or in a special room with ventilation openings to the outside
as prescribed by current regulations. If there are several burners or exhauster 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 materials or objects, corrosive gases, powders or vola-
tile substances.
For positioning, leave sufficient room around the modules for normal maintenance
work.
In particular, make sure the front door can open freely.
The air needed for combustion is drawn in through special openings in
the bottom of the door. Make sure these air passages are not obstructed
in any way.
2.4 Gas and water connections
Plumbing connections
Make the connections to the corresponding connections according to the fol-
lowing instructions. Make the generator connection so that its internal pipes are
free of stress. For correct operation and long life of the generator, the plumbing
system must be well-proportioned and always complete with all the accessories
that guarantee regular operation and running.
In particular, provide for all the protection and safety devices required by current standards for the complete
modular generator. They must be installed on the hot water circuit delivery piping, immediately after the
last module, within a distance of not more than 0.5 m, without shut-off devices in between. The unit is not
supplied with an expansion tank; its connection must therefore be carried out by the Installer.
A filter must be installed on the system return piping to prevent dirt or sludge from the system
clogging and damaging the heat generators.
The filter must be installed when replacing generators in existing systems. The manufacturer is not
liable for any damage caused to the generator by failure to install or inadequate installation of this
filter.
Characteristics of system water
In the presence of water harder than 25° Fr, suitably treated water must be used in order to avoid pos-
sible scaling in the boiler, caused by hard water, or corrosion produced by aggressive water. It should be
remembered that, because of the low thermal conductivity, scaling of just a few mm thick causes significant
overheating of the generator walls, resulting in serious problems.
Water treatment is indispensable in the 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 such cases, it is advisable to refill it with treated water.
Gas connection
The gas connection must be made to the corresponding connector with a rigid metal pipe.
The capacity of the gas meter must be sufficient for the simultaneous use of all equipment connected to it.
Make 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 loss of head.
It is advisable to fit a gas non-return valve on the outside of the modules, for shutting off the gas
supply even without opening the single modules equipped with key closing.
AIR
AIR

12
ECONCEPT 100
Connection side
1
2
3
1
2
3
4
1
2
3
1
2
3
4
Seals Flanges with
joining section
Blind flanges
Blind flanges Flanges with
joining section
Connection side
Fig. 5
Fig. 6a
Plumbing connection using one generator with a water trap
Plumbing connection using two or more generators with a water trap
Key
1- Gas inlet
2- System delivery
3- System return
4- Condensate drain
Connection instructions
Econcept 100 is equipped on the inside with 3 manifolds (gas, system delivery and return) and a condensate
drain pipe that facilitate cascade connections and also connection of the 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. 5)
• After establishing which side of the Econcept 100 module to make the water and gas connections, con-
nect the flanges with the joining section, contained in the kit, on that side after appropriately welding
them onto the system pipes so they are airtight. Make sure to correctly fit the special seals contained in
the kit.
• Connect a pipe Ø40 to the condensate drain pipe to evacuate the condensate produced during opera-
tion (see fig. 7).
• Fit the blind flanges contained in the kit on the opposite side of the module, interposing the special
seals.
To connect several modules in cascade (fig. 6a).
• Connect the first module to the system and gas pipes, as described above, but without fitting the blind
flanges on the opposite side of the module to that of the connection.
• Place the second module on that side, making sure to align the connection flanges and the condensate
drain pipe. Place 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 in 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 couple together the
condensate drain pipes of the two modules (see fig. 8).
• Tighten the nuts and repeat the connection operations for the next modules (max.5)
If using a water trap
• Fit the blind flanges on the last module, interposing the special seals.
If using a direct pump
• Connect the delivery to the return on the last module (see fig. 6b).

13
ECONCEPT 100
2
B
1
A
1
2 2
B
A
Fig. 7
Fig. 8
Condensate outlet connection using one generator
Condensate outlet connection using two or more generators
A- Place the pipe 1Ø40 (not supplied) on the side of the generator.
B- Slide the pipe 2 towards the side of the arrow for at least 2-3 cm to insert it in the pipe 1.
A- Place the pipe 1Ø40 (not supplied) on the side of the generator.
B- Slide the pipe 2(of each generator) towards the side of the arrow for at least 2-3 cm to insert it in the
pipe 1.
Connection side
1
2
3
1
2
34
Seals Flanges with
joining section
Delivery/return
connection
Plumbing connection using one or more generators with a direct pump
Fig. 6b

14
ECONCEPT 100
OFFON
OFF
ON
enerator 1 enerator 2
123456789101112
Operation enabling
signal
External sensor
Sequence adj.
connection
(OpenTherm)
Operation enabling
signal
External sensor
Sequence adj.
connection
(OpenTherm)
L
N
230V
50Hz
12-pole connector
6-pole connector
S3
T2
T1
Fig. 9
2.5 Electrical Connections
The unit must be installed in conformity with current national and local regulations.
Connections 230 Vac (6-pole connector)
Connection to the power mains
The generator must be connected to a single-phase power supply, 230 Volt-50 Hz, through the terminals
L, , and N.
Appliance 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 declines any liability for
damage caused by failure to earth the system. Also make sure the electrical system is adequate for
the maximum power absorbed by the unit, as specified on the boiler dataplate, in particular ensur-
ing that the section of the system’s cables is suitable for the power absorbed by the unit.
The generator is not provided with a cable for connection to the power mains. Connections to the mains
must be made with a permanent connection and equipped with a bipolar switch with contact opening dis-
tance of at least 3 mm, interposing fuses of max. 3A between the boiler and the line. Make sure to respect
the polarities (LINE: brown wire / NEUTRAL: blue wire / EARTH: yellow/green wire) in making connections
to the power mains.
The generator power cable must of type “HAR H05 VV-F” 3x0.75 mm2with max. outside diameter
of 8 mm. If the cable is damaged, switch off the unit and have it changed only by professionally
qualified personnel.
Fault signalling output connection
The 230 Vac output for signalling faults of boiler shell 1 is connected to terminals T1 (line) and T2 (neutral).
The 230 Vac output for signalling faults of boiler shell 2 is connected to terminals S3 (line) and T2 (neutral).
Both outputs are protected by fuses inside the corresponding control unit.
Make sure to respect the polarity.
Low voltage connections (12-pole connector)
An operation request contact, the Opentherm connection (communication protocol for cascade control
unit or control unit 0÷10Vdc) and the connection for the optional external sensor are provided for both
generators.

15
ECONCEPT 100
H
1/2H
1/2H
H
N
N W
Fig. 10
Positioning the external sensor
The external sensor should preferably be installed on the North, North-West wall or on the wall that most
of the main living room faces. The sensor must never be exposed to early morning sun, and in general, it
should not be exposed to direct sunlight; if necessary, it should be protected.
In any case, the sensor must not be installed near windows, doors, vents, flues or heat sources that could
affect its reading.
NB: The maximum permissible length of the electric cable connecting the boiler - external sensor is 50
m. A common 2-wire cable can be used.

16
ECONCEPT 100
2.6 Flue connection
• Manifold, ducts and flue must be suitably sized, designed and constructed in compliance with current
regulations. They must be made of suitable materials, i.e. resistant to heat and corrosion, smooth on
the inside and airtight. In particular, joints must be condensate tight. Also make provision for adequate
condensate drainage points, connected to a trap to prevent condensate in the flues from running into
the generators.
• Even in case of connection in bank, each single module can be connected to an individual flue of 1m
min. vertical length, equipped with a suitable cap. Installation must comply with the provisions of current
regulations.
• To connect several modules in cascade, a manifold with connection to
a single flue can be used. In this case, connect the fume outlets (Ø 150)
of the individual modules as shown in the figure, making sure to respect
the manifold and flue diameters given in the table opposite. The single
flues must be fitted to the manifold at an angle of approx. 30° to the
vertical (fig. 11).
• Air is drawn from the place of installation, which must be equipped with
adequate ventilation in accordance with current laws and regulations.
1
2
3
4
5
150
200
250
300
350
No. of
Econcept 100
modules
Ø
manifold/flue
Safety
elements
The manifold must slope towards the
condensate outlet by at least 3°.
Ø
150
30°
+3°
0,5 lt.
4
Fig. 11
2.7 Condensate drain
The boiler is equipped with an internal trap, for draining the
condensate, connected to an internal condensate drain manifold
4 fig. 12. Before start-up, open the cabinet and fill the trap with
approx. 0.5 l. of water.
Fig. 12

17
ECONCEPT 100
Fig. 13
3. SERVICE AND MAINTENANCE
3.1 Adjustments
All adjustment and conversion operations must be carried out by Qualified Personnel such as Local Technical
Assistance Service personnel.
Ferroli declines any liability for damage or injury caused by unqualified and unauthorized persons tampering
with the appliance.
Gas conversion
The unit can run on Natural Gas or LPG and is factory-set for use with one of the two gases, as clearly
shown on the packing and on the appliance dataplate. Whenever a different gas to that for which the unit
is preset has to be used, a conversion kit will be required, proceeding as follows:
1Unscrew the gas fittings Alocated on the air/gas mixers B.
2Change the nozzles in the mixers with those contained in the conversion kit.
3Refit the fittings Aand check that the connections are tight.
4Apply the sticker contained in the conversion kit, near the dataplate.
NB:
For the nozzle sizes, see the technical data table

18
ECONCEPT 100
Setting
70°
Adjustable from:
30 to 90°
Boiler parameter adjustment
Press the “mode” and keys at the same time for more than 3 seconds to access the boiler
parameter menu.
Then press to scroll through the parameters, whereas the set values can be modified with the
and keys.
For the modification to be active, press “confirm”.
Temperature adjustments
Press “Mode” key to access the user menu (see chap. 1 for a full description) where it is possible to
edit:
Par. “1” • System temperature
The generator is equipped with a safety device that temporarily stops operation in case of too high
temperatures.
3.2 System start-up
Commissioning must be performed by Qualified Personnel such as those of our Sales Organization and the
local Customer Technical Assistance Service.
The first start-up is free of charge and must be requested as indicated on the sticker on the generator.
Checks to be made at first start-up, and after all maintenance operations that involved disconnecting from
the systems or intervention on safety devices or parts of the generator:

19
ECONCEPT 100
Before lighting the generator:
• Open any shut-off valves between the generator and the systems
• Check the tightness of the gas system, proceeding with caution and using a soap and water solution to
detect any leaks in connections.
• Fill the system as indicated above and make sure all air contained in the generator and the system has
been vented by opening the air valve inside the unit and any air valves on the system.
• Make sure there are no water leaks in the system, connections or generator.
• Make sure the electrical system is properly connected.
• Make sure the unit is connected to a good earthing system.
• Make sure the unit is correctly connected to the condensate draining system and that the condensate
evacuation system works properly.
• Make sure the pressure and gas flow values are those required for heating.
• Make sure there are no flammable liquids or materials in the immediate vicinity of the generator.
Turning on the generator:
• Open the gas valve ahead of the generator.
• Vent the air from the pipe ahead of the gas valve.
• Turn on the switch or insert the plug ahead of the generator
• Press the two boiler shell switches (ON position).
• The generator switches on and runs a complete self-test cycle of approx. one minute, checking correct
operation of the main parts. The display shows the following in sequence:
Software release
Parameter version
Operation in test mode - ( )
• If the cycle is correctly executed:
- If there is no demand for heating, the display shows a lower-case “ o “ (standby mode) followed by
the temperature value of the delivery sensor. Then use the room thermostat or the remote control to
activate heating
- If there is a demand for heating, the display goes from standby “ o “ to the heating phase “ c “ and
the generator starts automatically, controlled by its adjustment and safety devices.
- If any faults are detected in the self-test cycle or during ignition, the display shows the corresponding
error code and the generator shuts down. Wait about 15 seconds and press reset. The reset generator
will repeat the ignition cycle. If the generator fails to light even after the second attempt, consult the
“Troubleshooting” section.
Note In case of a power failure while the generator is working, the burner shuts down. When power
returns, the boiler runs the self-test cycle again, after which the burner will automatically re-ignite
(if there is still demand for heat).
Checks during operation
• Check the tightness of the gas supply circuit and water systems.
• Check the efficiency of the flue and air/fume ducts while the generator is working.
• Check that the water is circulating properly between the boiler and the systems.
• Make sure the gas valve modulates correctly both in the heating and domestic hot water production
phases.
• Check correct ignition of the boiler by performing several tests, turning it on and off with the room
thermostat or remote control.
• Make sure the gas consumption indicated on the meter corresponds to that given in the technical data
table.
• Make sure the parameters are programmed correctly and perform any required customization (compen-
sation curve, power, temperatures, etc.).

20
ECONCEPT 100
3.3 Maintenance
The following operations are strictly reserved for Qualified Personnel, such as those of our Sales Organiza-
tion or the local Customer Technical Assistance Service.
Seasonal inspection of the generator and flue
Have the following checks carried out at least once a year:
• The control and safety devices (gas valve, flow meter, thermostats, etc.) must function correctly.
• The fume ducts must be free of obstructions and leaks.
• The condensate evacuation system must be efficient without any leaks or obstructions.
• The gas and water systems must be tight.
• The burner and exchanger must be clean. Follow the instructions in the next paragraph.
• The electrodes must be free of scale and correctly positioned.
• The water pressure in the system when cold must be approx. 1 – 1.5 bar; otherwise bring it to that
value.
• The gas flow and pressure must correspond to that given in the respective tables.
• The circulating pumps must not be blocked.
Cleaning the generator and burner
The body and burner must not be cleaned with chemical products or wire brushes.
Particular attention must also be paid after performing all the operations, in checking and carrying out all
the switch-on and operation phases of the thermostats, gas valves and circulating pumps.
After these checks, make sure there are no gas leaks.
Shutting off the exchangers from the system
To isolate the single exchanger from the system and allow maintenance operations, firstly shut off the return
valve “1” and then the three-way delivery valve “2”. In this way the three-way valve “puts the exchanger
in communication with the atmosphere”, causing it to discharge into the special manifold “4”.
4
1
2