Ferroli ECONCEPT SOLAR ST, Instructions For Use, Installation And Maintenance

Page 1: ...cod 11 2010 Rev 00 ECONCEPT SOLAR ST INSTRUCTIONS FOR USE INSTALLATION AND MAINTENANCE ...

Page 2: ...gulations and the manufacturer s instructions Incorrect installation or poor maintenance can cause damage or physical injury The manufacturer de clines any responsibility for damage caused by er rors in installation and use or by failure to follow the manufacturer s instructions Before carrying out any cleaning or maintenance oper ation disconnect the unit from the electrical power sup ply using t...

Page 3: ... 14 2 5 Electrical connections 15 2 6 Fume ducts 16 2 7 Condensate drain connection 20 3 Service and maintenance 21 3 1 Adjustments 21 3 2 Starting 22 3 3 Maintenance 26 3 4 Trouble shooting 27 4 Technical data and characteristics 29 4 1 Dimensions and connections 29 4 2 General view and main components 30 4 3 Water circuit 31 4 4 Technical data table 33 4 5 Diagrams 34 4 6 Wiring diagram 36 4 7 D...

Page 4: ...rol system The boiler shell consists of an aluminium lamellar exchanger and a ceramic premix burner equipped with electronic ignition and ionisation flame control modulating speed fan and modulating gas valve The boiler is arranged for connection to one or more solar collectors which are used for domestic hot water production In fact the unit has a special incorporated stratified solar hot water t...

Page 5: ...let temperature setting flashing dur ing Exchanger protection function 15 Eco Economy or Comfort mode 16 External sensor temperature with optional ex ternal probe 17 Appears on connecting the external Probe or the Remote Timer Control optionals 18 Room temperature with optional Remote Timer Control low temperature zone 19 Burner lit and actual power flashing during Flame protection function 20 Ant...

Page 6: ...arks detail 11 fig 1 light up as the hot water tank sensor temperature reaches the set value fig 3 Exclude hot water tank economy Hot water tank temperature maintaining heating can be excluded by the user If excluded domestic hot water will only be delivered by the solar circuit the latter is managed by the controller DBM29 whose specifications are given in cap 4 7 DBM29 ECOTRONIC tech Solar Contr...

Page 7: ...h that prescribed in sec 2 3 Boiler lighting Switch on the power to the unit fig 5 Boiler ignition For the following 180 seconds the display will show FH which identifies the heating system air venting cycle During the first 5 seconds the display will also show the card software version Open the gas cock ahead of the boiler When the message FH disappears the boiler is ready to operate automaticall...

Page 8: ...r 1 second fig 8 The display will activate the Summer symbol part 27 fig 1 the boiler will deliver tap water only The antifreeze system stays on To turn off Summer mode press button part 6 fig 1 again for 1 second Heating temperature adjustment high temperature zone 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 9 This temperature be...

Page 9: ...t the system water according to the required room temperature For operation with remote timer control refer to the relevant instruction manual Domestic hot water DHW temperature adjustment 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 10 Sliding temperature When the optional external probe is installed the control panel display detail 5...

Page 10: ...adjustment mode Compensation curve and curve offset Low Temperature Zone with optional Remote Timer Control connected Refer to the relevant instruction manual Compensation curve and curve offset Low Temperature Zone without optional Remote Timer Con trol connected Press the ECONOMY COMFORT button detail 7 fig 1 for 10 seconds parameter o01 or the actual compensation curve is displayed which can be...

Page 11: ...il 5 fig 1 shows the actual room temperature read by the Remote Timer Control Table 1 DHW temperature adjustment Adjustment can be made from the Remote Timer Control menu and the boiler control panel Eco Comfort selection On disabling DHW from the Remote Timer Control menu the boiler selects the Economy mode In this condition the ECONOMY COMFORT button detail 7 fig 1 on the boiler panel is disable...

Page 12: ...pressure fault Operate the filling cock detail 1 fig 16 and bring the system pressure to a value above 1 0 bar At the bottom of the boiler there is a pressure gauge detail 2 fig 16 to show the pressure even when there is no power supply fig 16 Filling cock A Once the system pressure is restored the boiler will activate the 180 second air venting cycle indicated on the display by FH At the end of t...

Page 13: ...esiduals or impurities that could affect prop er operation of the unit B Also a filter must be installed on the system return piping to prevent impurities or sludge from the system clog ging and damaging the heat generators The filter must be installed when replacing generators in existing systems The manufacturer declines any li ability for damage caused to the generator by failure to install or ...

Page 14: ...ed water is advisable in order to avoid possible scaling in the boiler The treatment must not in any case reduce the hardness to values below 15 F Decree 236 88 for uses of water intended for human consumption Water treatment is indispensable in the case of very large systems or with frequent replenishing of water in the system If partial or total emptying of the system be comes necessary in these...

Page 15: ...VV F 3x0 75 mm2 cable with a maximum outside diameter of 8 mm Solar collector temperature probe The unit is provided with a temperature probe for positioning on the circuit at the outlet of the last collector The probe must be connected to the controller after carrying out the solar circuit filling operations described in sec 2 3 The con troller is located on the left side on the back of the elect...

Page 16: ...gurations may be ex pressly limited or not permitted by law standards or local regulations Before proceeding with installation check and carefully observe the above mentioned prescriptions Also comply with the provisions on the positioning of wall and or roof terminals and the minimum distances from windows walls ventilation openings etc B This C type unit must be installed using the fume suction ...

Page 17: ...ts Before proceeding with installation check with table 2 that the maximum permissible length is not exceeded bearing in mind that every coaxial bend gives rise to the reduction indicated in the table For example a Ø 60 100 duct comprising a 90 bend 1 horizontal metre has a total equivalent length of 2 metres Table 2 Max length coaxial ducts ECONCEPT SOLAR ST 18 ECONCEPT SOLAR ST 25 Coaxial 60 100...

Page 18: ...ngth has not been exceeded by means of a simple calculation 1 Establish the layout of the system of split flues including accessories and outlet terminals 2 Consult the table 4 and identify the losses in meq equivalent metres of every component according to the instal lation position 3 Check that the sum total of losses is less than or equal to the maximum permissible length in table 3 Table 3 Max...

Page 19: ...r quadrangular cross section with a vertical progression and with no constrictions Have the ducts conveying the hot fumes adequately distanced or isolated from combustible materials Be connected to just one unit per floor Be connected to just one type of unit or all and only forced draught units or all and only natural draught units Have no mechanical suction devices in the main ducts Be at a lowe...

Page 20: ...n The boiler is equipped with an internal trap to drain condensate Fit the inspection union A and flexible tube B pressing it in for approx 3 cm and securing it with a clamp Fill the trap with approx 0 5 l of water and connect the flexible tube to the drainage system fig 25 ...

Page 21: ...roceeding as follows 1 Remove the casing 2 Open the sealed chamber 3 Replace the nozzle A inserted in the mixer with that contained in the conversion kit 4 Reassemble and check the tightness of the connection 5 Apply the label contained in the conversion kit near the dataplate 6 Refit the sealed chamber and casing 7 Modify the parameter for the type of gas put the boiler in standby mode press the ...

Page 22: ...the RESET button within 5 seconds and the max power will remain that just set Exit TEST mode see sec 3 1 3 2 Starting Before lighting the boiler Open any on off valves between the boiler and the systems Check the tightness of the gas system proceeding with caution and using a soap and water solution to detect any leaks in connections Check correct prefilling of the expansion tank ref sec 4 4 Fill ...

Page 23: ...ing of the parameters and carry out any necessary customization compensation curve power temperatures etc Solar circuit The solar circuit is managed by the Controller DBM29 whose specifications are given in cap 4 7 DBM29 ECOTRONIC tech Solar Controller To start the solar system it is necessary to use the special filling pump and carry out the following procedure respecting the order of steps descr...

Page 24: ...ain pipe connected to the cock 11 Open the cock 11 and cock 1 depressurising the solar circuit Check the closing of the system venting device 17 Using the pump 16 pump the solar heat transfer fluid from the container 10 in the solar circuit for about 10 15 min utes depending on the length of the system pipes Check the filter 9 and clean it if necessary 3 Filling the solar circuit Check the solar e...

Page 25: ...imiter Activate the Flow limiter adjustment mode see specifications in cap 4 7 DBM29 ECOTRONIC tech Solar Controller Using an adjusting wrench 9 mm operate on the control of the limiter 4 fig 31 and adjust the flow rate Deactivate the Flow limiter adjustment mode see specifications in cap 4 7 DBM29 ECOTRONIC tech Solar Controller 6 Solar collector temperature sensor To connect the solar collector ...

Page 26: ...th a soft damp cloth if necessary soaked in soapy water Do not use any abrasive detergents and solvents Solar circuit Make sure to periodically check the condition and pressure of the fluid in the system when cold at least once every 2 3 years if possible at the end of the most critical period in relation to the risk of prolonged stagnation of the fluid in the collectors overheating of the fluid d...

Page 27: ...on of the heating sensor No water circulation in the system Check the circulating pump Air in the system Vent the system A04 Fume extraction duct safety device activation Fault F07 generated 3 times in the last 24 hours See fault F07 A05 Fan protection activation Fault F15 generated for 1 hour consecutive See fault F15 A06 No flame after ignition stage 6 times in 4 min Ionisation electrode fault C...

Page 28: ... Solar Collector PT1000 sensor The sensor fault understood as a short circuit or open circuit causes deactivation of the Solar Pump and shutter closing The protection is immediately deactivated on eliminating the fault To signal this fault the symbol S3 will be deactivated whereas the Fault symbol and the backlight will start flashing F84 Solar Collector Return NTC sensor The sensor fault understo...

Page 29: ... 10 System delivery 11 System return 192 Recirculation 320 Low temperature delivery 321 Low temperature return 323 Mixed DHW outlet 327 Solar system delivery 328 Solar system return 1057 180 120 221 600 180 120 221 120 180 Mod 18 Mod 25 600 1800 47 110 90 48 57 68 41 55 41 44 54 45 327 Ø 3 4 328 Ø 3 4 321 Ø 3 4 11 Ø 3 4 8 Ø 3 4 7 Ø 1 2 192 Ø 3 4 10 Ø 3 4 323 Ø 3 4 320 Ø 3 4 ...

Page 30: ...N cod 11 2010 Rev 00 4 2 General view and main components fig 34 Main components 5 29 191 56 82 188 22 161 14a 36 246 32 95 196 278 16 193 44 194 179 14b 14c 318a 315a 180 74 310 130 312 308 40 316 314 233 186 179 317a 319a ...

Page 31: ...35 Water circuit 56 44 14a 32 11 10 7 95 241 246 36 186 161 278 16 196 145 179 179 194 193 154 97 191 233 155 130 311 309 310 Valvola regolazione portata 314 313 180 321 316 315a 317a 319a 320 318a 40 322 323 8 179 14b 308 179 145 326 74 Indicatore di portata 14c 312 ...

Page 32: ...ure probe 161 Condensing heat exchanger 179 Non return valve 180 Hot water tank 186 Return sensor 188 Ignition electrode 191 Fume temperature sensor 193 Trap 194 Exchanger 196 Condensate tray 233 Hot water tank drain cock 241 Bypass 246 Pressure transducer 256 Modulating heating circulating pump signal 278 Double sensor Safety Heating 308 Solar expansion tank 309 Solar system filling cock 310 Sola...

Page 33: ... G20 m3 h 0 32 0 56 Gas supply pressure G31 mbar 37 37 Max gas delivery G31 kg h 1 41 2 11 Min gas delivery G31 kg h 0 23 0 41 Max working pressure in heating bar 3 3 PMS Min working pressure in heating bar 0 8 0 8 Max heating temperature C 95 95 tmax Heating water content litres 1 1 5 Heating expansion tank capacity litres 8 8 Heating expansion tank prefilling pressure bar 1 1 Max working pressur...

Page 34: ...T SOLAR ST 18 A Boiler pressure losses 1 2 3 Circulating pump speed Low Temperature zone circulating pumps Head Pressure loss ECONCEPT SOLAR ST 18 B Boiler pressure losses 1 2 3 Circulating pump speed 0 1 2 3 4 5 6 7 0 500 1 000 1 500 2 000 Q l h H m H2O A 3 2 1 0 1 2 3 4 5 6 7 0 500 1 000 1 500 2 000 Q l h H m H2O B 3 2 1 ...

Page 35: ... ST 25 A Boiler pressure losses 1 2 3 Circulating pump speed Low Temperature zone circulating pumps Head Pressure loss ECONCEPT SOLAR ST 25 B Boiler pressure losses 1 2 3 Circulating pump speed 0 1 2 3 4 5 6 7 0 500 1 000 1 500 2 000 Q l h H m H2O 3 2 1 A 0 1 2 3 4 5 6 7 0 500 1 000 1 500 2 000 Q l h H m H2O B 3 2 1 ...

Page 36: ...8 139 A 138 DBM05D DSP05 256 310 314 319a 318a 317a DBM29 FZ4B 72 311 3 9 KOhm 32 16 44 N L 230V 50Hz 130 246 GND OUT 5V 1 2 3 4 5 6 MODUL DIRECT SENSOR 7 8 MIX 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 315a A B C 1 2 3 4 5 6 7 8 9 10 11 12 11 10 9 8 7 6 5 4 3 2 1 3 2 1 2 1 ...

Page 37: ... with room thermostat on the low temperature zone On con necting the remote timer control it will be necessary to configure the controller FZ4B To do this press the AUTOCFG button see fig 37 until all the LEDs of theFZ4B card flash The boiler will then be ready to operate with remote timer control on the low temperature To reconnect the room thermostat in place of the remote timer control carry ou...

Page 38: ... collector temperature 13 Activated Solar collector temperature ok normal operation Deactivated solar collector temperature sensor fault Flashing solar collector limit temperature function 14 Activated solar collector return temperature ok normal operation Deactivated solar collector return temperature sensor fault 15 Activated boiler hot water tank temperature correct normal operation Flashing ho...

Page 39: ...mperature differential parameter value Installer parameter default value equal to 10 C the Solar Circulating Pump works at speed 2 55 To signal this mode the symbol B will be lit up 3 If the difference between the temperature of Solar Collector Sensor S3 and the Solar Collector Return Sensor S4 is greater than the Minimum Solar Circulating Pump Modulation temperature differential parameter value I...

Page 40: ...stment mode To signal the Flow Limiter Adjustment mode the Radiator and Tap symbols will start flashing together The Solar Cir culating Pump is immediately activated in continuous mode and at speed 5 Max power 100 The Flow Limiter Adjustment mode ends automatically after 2 minutes or by pressing the button for 10 seconds System Cooling function Collector and Hot Water Tank This function depends on...

Page 41: ... value Installer parameter default value equal to 80 C 2 C Solar Collector Limit Temperature function The Solar Circulating Pump will be deactivated if the temperature of Solar Collector Sensor S3 becomes higher than or equal to the Collector limit temperature parameter value Installer parameter default value equal to 140 C in this case as well as shutting down the Solar Circulating Pump the ECOTR...

Page 42: ...ashing Fault 84 Solar Collector Return NTC Sensor S4 faulty The fault understood as a short circuit or open circuit of the sensor does not cause deactivation of the Solar Circulating Pump The system must simply work as though the Basic System were set On eliminating the fault the protection is immediately deactivated To signal this fault the symbol S4 will be deactivated whereas the Fault symbol t...

Page 43: ...5 1519 75 10 19854 10 1038 5 140 1539 15 15689 15 1057 75 145 1558 25 20 12483 20 1077 150 1577 5 25 9999 25 1096 25 155 1596 75 30 8060 30 1115 5 160 1616 35 6537 35 1134 75 165 1635 25 40 5332 40 1154 170 1654 5 45 4374 45 1173 25 175 1673 75 50 3608 50 1192 5 180 1693 55 2991 55 1211 75 185 1712 25 60 2492 60 1231 190 1731 5 65 2086 65 1250 25 195 1750 75 70 1754 70 1269 5 200 1770 75 1481 75 1...

Page 44: ...llector limit temperature C 110 160 C 140 C P06 System cooling parameter 0 Off 1 On 0 1 1 On P07 System cooling function activation collector temperature C 100 150 C 120 C P08 Collector min limitation parameter 0 Off 1 On 0 1 0 Off P09 Collector min temperature C 10 90 C 10 C P10 Antifreeze protection function parameter 0 Off 1 On 0 1 0 Off P11 Antifreeze temperature C 1 10 C 4 C P12 Tank cooling ...

Page 45: ... with parameter P26 1 Stand alone t03 S3 Solar collector PT1000 sensor C between 01 and 175 C t04 S4 Solar Return Collector NTC sensor C between 01 and 125 C F05 Solar circuit flow rate Lt_min Only with Flowmeter connected and activated 00 99 Lt_min P06 Actual modulating circulating pump speed 40 Speed 1 100 Speed 5 0 100 Ht No hours ECOTRONIC Tech operation Supply between 0 and 9999 hours H01 Fau...

Page 46: ...f the following parameters must be correctly set P16 Solar circuit max flow rate l min P18 Antifreeze liquid protection rating P23 Solar circulating pump operation 0 On Off Accumulated energy kWh Value P16 60 x deltaT S3 S4 x 1 163 x 100 Value P18 100 1000 MODULATING CIRCULATING PUMP WITH FLOWMETER The value of the following parameters must be correctly set P18 Antifreeze liquid protection rating ...

Page 47: ...0 C 02 P02 Zone1 Max Temperature 10 90 C 40 C 70 80 C 03 P03 Zone1 calculated set point offset 0 40 C 10 C 0 C 04 P04 Do not modify 10 90 C 90 C 05 P05 o01 Zone1 External Probe Curve 0 10 0 06 P06 o02 Zone1 External Probe Offset 20 40 C 30 C 07 P07 Zone2 Min Temperature 10 90 C 10 C 08 P08 Zone2 Max Temperature 10 90 C 80 C 09 P09 Zone2 calculated set point offset 0 40 C 0 C 10 P10 DO NOT MODIFY 1...

Page 48: ...thermostat fig 39 Compensation curves fig 40 Example of parallel compensation curve shift The Mixing valve on off time and Mixing valve on time for C parameters are used for adjustment of the mixing valve Example with the parameters set to the default value therefore 15sec and 1sec C if the delivery temperature re quired for the mixed zone is 32 C and the actual delivery temperature measured by th...

Page 49: ...tion The controller indicates the boiler operating mode and its faults through the incorporated display St means Standby no demand in progress CH means that the zone controller requests the boiler for activation of heating mode DH means Domestic Hot Water production The fault codes are given below The fault codes are also displayed on the corresponding menu of the Remote Control during normal oper...

Page 50: ... controller The settings relevant to DHW such as Domestic Hot Water temperature weekly time programming with boiler prearranged see relevant documentation etc are managed in parallel these are modified through the temperature zone Remote Controls In case of DHW weekly time program ming the zone controller overlaps programmes coming from the single Remote Controls Conversion of low temperature zone...

Page 51: ......

Page 52: ...FERROLI S p A Via Ritonda 78 a 37047 San Bonifacio Verona ITALY www ferroli it ...