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• On the Ferroli Zefiro Eco 11 instantaneous gas water-heater the code E3 = “flame not proved after three ignition attempts (lock-out)”.
• In practice the control board ran the normal start-up sequence (flow sensor → fan → spark generator → opens gas valve) but did not receive a valid ionisation signal, so it shut the appliance down for safety. (Fan only on room-sealed versions.)
Key points
– Most frequent causes: dirty/mis-gapped or damaged ignition/ionisation electrode, poor electrode cabling or earthing, weak spark module, low/absent gas pressure, or blocked burner.
– Secondary causes: partially blocked flue / inadequate draught, leaking or kinked air-pressure-switch tubes, failing fan, or, rarely, a faulty main PCB.
– Never bypass any safety component; if in doubt call a certified gas engineer.
Sequence to be satisfied
a. Water flow > 2 l/min closes reed/flow switch → PCB wakes up
b. (Room-sealed models) Fan starts; air-pressure switch (APS) must close within ~3 s
c. Ignition transformer produces ≈8-12 kV sparks at electrode tip
d. Gas valve opens; within 3-4 s flame must touch the ionisation probe
e. Flame rectification current (~1–5 µA) flows to PCB; if absent ⇒ E3
Component-level root-cause map
• Ignition/ionisation electrode
– Carbon/oxide layer, cracked ceramic, bent tip; wrong gap (spec 3–4 mm)
– High-voltage lead tracking to earth, loose spade connector
• Gas circuit
– Service tap partially closed, inlet pressure <20 mbar (NG) / <37 mbar (LPG)
– Wrong injector size after gas-type change, blocked burner ports
– Faulty gas valve coil (800–1200 Ω) or stuck valve
• Combustion air path
– Blocked concentric flue terminal (leaves, bird nest, ice) → insufficient draught
– Fan bearings dry, seized or running slow → APS does not prove airflow
– Split / water-filled silicone tubes on APS; diaphragm stuck
• Electrical / PCB
– Missing 230 V to fan or gas valve, poor earth reference → no flame current return
– Damaged flame-detection op-amp on PCB (rare; diagnose by exclusion)
Interaction of faults
A weak fan or partially blocked flue may still let the burner light in calm weather but fail in wind; this explains intermittent E3 reports seen in forums. In hard-water areas limescale on burner surfaces shifts the flame away from the probe, again causing sporadic E3.
Online service bulletins (2023–2024) from Ferroli and user reports on Elektroda and HWZ forums consistently list “failure to detect flame / ignition fault” as the official meaning of E3 for Zefiro Eco series. Recent field data show:
• ≈60 % cases solved by cleaning/re-gapping the electrode and burner.
• ≈25 % relate to APS/fan/flue issues, especially after long idle periods.
• <10 % end with PCB replacement.
Modern revisions (FW ≥1.08) add a self-clear feature: five minutes after lock-out the board retries ignition once before demanding a manual reset; older boards need the reset button pressed.
Ionisation principle: a metal rod in the flame rectifies the applied AC; the PCB senses a DC micro-current. Any high resistance in the return (corroded earth strap, painted bracket) will suppress that current.
Testing: connect micro-ammeter in series between probe and PCB; expect 1–5 µA with flame established. Zero µA → flame not touching probe or circuit open.
• Gas appliances must be serviced by personnel holding the appropriate national licence (e.g., Gas-Safe UK, RGII IE, RGE FR).
• Tampering with flue-safety devices or bypassing APS violates EN 26 / EU Gas Appliances Regulation 2016/426 and can lead to CO poisoning liabilities.
Common pitfalls & remedies
• Forgotten earth wire on electrode bracket → E3 every time.
• Converted to LPG but jets for NG left in place → flame lifts, E3.
• Condensate collector full → blocks inner flue, fan can’t create pressure → APS open, E3.
• Model variants (open-flue “11 OF” vs room-sealed “11 C11”) share E3 meaning, but the presence of fan/APS applies only to the latter.
• Heat-exchanger corrosion cited in some forums is usually a secondary effect causing water drips on electrodes, again leading to flame loss; the code itself still denotes non-detection of flame.
• Investigate retrofit ionisation-current diagnostics via the service port to allow predictive maintenance.
• Explore use of non-contact flame UV sensors for higher reliability in future design iterations.
• Monitor field data on APS failure rates vs fan PWM profiles to refine preventive service intervals.
Error E3 on the Ferroli Zefiro Eco 11 is a lock-out caused by the appliance not confirming a stable flame. In order of likelihood check/clean the ignition-ionisation electrode and burner, verify gas pressure, ensure unobstructed flue and correct fan/APS operation, and finally rule out wiring or PCB defects. Always follow gas-safety legislation; if basic cleaning and visual checks do not clear the fault, engage a qualified technician.
