Appr. Nr. B 9709a - ce n ° 0063 at 4967 installation, servicing and user instructions g.C. No: 47-26701 industrie falcon c opper w all -m ounted c ombination , g as f ired b oiler for c entral h eating and d omestic h ot w ater p roduction , f an a ssisted , r oom s ealed c ompartment , e lectronic ...
2 industrie falcon 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" "all corgi registered installers carry a corgi id card and have a registration number. ...
3 falcon industrie key 1. Description ............................................................................................................................................. 4 2. Technical and dimensional characteristics ............................................................................
4 industrie falcon 1. Description 1.01 introduction the falcon is defined as a “room sealed” combination boiler, all air required for combustion is taken from outside the room in which it is installed. It is a new high performance gas fired heat generator for central heating and domestic hot water p...
5 falcon industrie fig. 1 2. Technical and dimensional characteristics 2.01 technical information falcon boilers are central heating and domestic hot water heat generators and are produced as standard to function with natural gas or liquid petrolium gas converted appliances. Key 1 - 3/4" central hea...
6 industrie falcon n.B. - the gas pressures at the burner and gas flows during the central heating phase given in the table refer to nominal boiler output . To reduce this output (where necessary), gas pressure must be reduced until the required output level is reached (see figures 4 and 5). During ...
7 falcon industrie 2.03 boiler water flow diagram fig. 3 2.02 boiler main components fig. 2 out in min air in air in flue out c.H. Out d.H.W. Out gas in d.H.W. In c.H. In in out min 50 70 40 off reset on bar 60 80 ° c ° c 0 5 1 2 3 4 6 + - r over ride x x 4 auto p o i p 98 63 157 145 62 22 82 81 10 ...
8 industrie falcon 2.04 central heating adjustment (not normally required) to adjust boiler heat input (thus also regulating heat output to the central heating water) simply adjust the main burner via the electronic control board (fig. 4, 5 and see paragraph 5.04 page 24). The diagrams indicate the ...
9 falcon industrie fig. 8 pressure loss diagram sizing of additional expansion vessels: deduct from the value given in the table the 8 litre vessel supplied. Note: 1. Fill c.H. Installation to min. 1.5 bar. 2. Select the expansion vessel for a system pressure of 2.0 bar. 3. Expansion vessel must be ...
10 industrie falcon 3. Installation details 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 prac...
11 falcon industrie fig. 9 central heating detailed recommendations are given in bs6798, bs5449, bs6700 and cp342 part 2. Pipework not forming part of the useful heating suface should be insulated to prevent any heat losses or possible freezing (i.E. In roof spaces or ventilated underfloor spaces). ...
12 industrie falcon terminal position position minimum spacing mm a directly below an openable window, air vent, or any other ventilation opening 300 b below gutters, soil pipes or drainpipes 75 c below eaves 100 d below a balcony 100 e from vertical drainpipes or soilpipes 75 f from internal or ext...
13 falcon industrie 3.01 drilling template (top flue application) select suitable mounting position for boiler, using the template mark flue outlet and boiler mounting points. Drill two 10mm holes 90mm deep to accept the wall plugs, fit wall plugs. Fit two special wall plugs on the wall as described...
14 industrie falcon 3.02 restrictor for boiler operation, the restrictor supplied with the unit must be mounted following the instructions below. Determine the correct size of flue restrictor required. Before inserting the flue gas duct in the boiler, check that the restrictor fitted is correct and ...
15 falcon industrie a 90 ° bend (fig. 16) is supplied for the horizontal connection of air and flue gas pipes. This can be oriented towards the chosen wall in degrees of 45 ° . 3.03 top outlet concentric flue connection 3.03.1 vertical concentric connection l a=l+(85-90)mm Ø2 Ø1 25-30 mm 60 Ø2 Ø1 Ø1...
16 industrie falcon fig. 17 notes on concentric horizontal installation to locate the centre of the hole for passing the pipes through the wall, refer to fig. 13. Bear in mind that the two concentric pipes must slope downwards away from the boiler at a rate of about 3 mm/m to avoid rainwater enterin...
17 falcon industrie fig. 19 3.04 top outlet: two pipe flue system 3.04.1 two pipe connection two separate ducts Ø80 for air intake and flue gas discharge can be directly connected to the boiler. Fit separate air intake plate. Connect flue duct to central hole Ø80 and air duct to left or right air in...
18 industrie falcon 3.04.2 (continued) tab. 1 - pipes and fittings reduction table air flue v ertical horizontal v ertical horizontal description male -fem ale flue Ø80 female -fem ale bend 45 ° Ø80 female -fem ale bend 90 ° Ø80 male -fem ale bend 90 ° Ø80 pipe fitting m/m/f Ø80 with inspecting plug...
19 falcon industrie for further accessories please refer to: "flue system manual for room sealed boiler" attention: flow resistance (reduction) equivalent in- cluded between 38 and 48 (see table on page 14) remove the flue diaphragm. The flue and air pipes must have an inclination downward equal to ...
20 industrie falcon 3.05 connecting the central heating and domestic hot water circuits connect to the relevant connections as indicated in fig. 1. Connect the pressure relief valve discharge pipe (15mm) to the outside of the building, where possible over a drain. The discharge must be such that it ...
21 falcon industrie note : if the power supply cable has to be replaced, use “0.75mm (24/0.20) heat resisting cable only to bs6500 with a maximum external diameter of 8 mm. Note - when connecting a room thermostat or external timer, do not link the power supply of these devices to the switching cont...
22 industrie falcon 4. Commissioning and testing 4.01 checks to be carried out before starting up for the first time when starting the boiler up for the first time check: • that the gate valves between the boiler and central heating systems are open; • that the central heating system is filled and v...
23 falcon industrie 5. Adjustment and gas conversion 5.01 adjusting the pressure and flow rate to the main burner this boiler operates on the flame modulation principle. It has two fixed pressure values, minimum and maximum, which must be as shown in the table (pages 6), whichever type of gas is use...
24 industrie falcon 5.04 adjusting maximum output for central heating system (fig. 25) this adjustment must be carried out electronically using the “p3” adjustment screw starting with a cold central heating system. Connect a pressure gauge to the pressure test point downstream of the gas valve. Rota...
25 falcon industrie 6. Maintenance and cleaning the following operations must be carried out by corgi registered engineers only. 6.01 annual servicing the following should be checked at least once a year: • water pressure in the central heating system when cold should be about 1 bar. If this is not ...
26 industrie falcon 20. Reconnect gas union and tighten. 21. Refit combustion chamber cover, secure with screws. 22. Examine seals on room sealed cover refit cover and secure with screws. 23. Turn on gas and electricity. 24. Fire boiler and check all gas joints for soundess. 25. Check flame picture ...
27 falcon industrie 7. Replacement of parts 7.01 initial procedure a) the boiler is cold, electricity supply is isolated, and the gas supply is turned off at the inlet of the boiler b) for replacement of parts where water connections are broken, it will be necessary to isolate and drain either or bo...
28 industrie falcon 7.07 d.H.W. Temperature sensor or central heating temperature sensor (fig. 31) • isolate electricity and water supplies • remove outer case (two screws bottom rear corners) • remove the two securing screws and lower control panel • identify the sensor from figure 31 • disconnect ...
29 falcon industrie 7.08 removal of burner (fig. 32) • isolate gas and electricity supplies • remove outer case (two screws bottom rear corners) • remove room sealed cover • disconnect ignition and flame rectification leads "a" • undo gas rail union "b" • undo two screws securing the burner assembly...
30 industrie falcon 7.12 spark or flame detect electrode (fig. 34) • isolate gas and electricity supply • remove outer case (two screws bottom rear corners) • open room sealed compartment and combustion chamber • identify electrode from fig. 34 • unplug electrical connection "a" from sensing electro...
31 falcon industrie b d c a f e 7.14 pump (fig. 36) replacement of pump head • isolate electricity and flow and return pipes • remove casing (two screws bottom rear corners). • remove the two securing screws and lower control panel • release pressure from boiler via pressure relief valve • unplug th...
32 industrie falcon 8. Fault finding before beginning any fault finding ensure that gas, water and electricity are available. Warning : do not link any terminals on block x8 or x4 as this will damage the pcb beyond repair. 8.01 operating sequence with the power established the boiler is in its stand...
33 falcon industrie in order, the five lights indicate: 1 mains electricity on/low voltage on 2 flow meter operated 3 c.H. Controls, room thermostat/clock and temperature regulator calling 4 c.H. Waiting time (approximately three minutes) 6 low water pressure switch - warning note: always check for ...
34 industrie falcon 8.04 temperature sensors (thermistors) identical, but individual, negative temperature co-efficient (ntc) thermistors are fitted in the c.H. And d.H.W. Outlets from the heat exchanger. As the water temperature increases the resistance in the thermistor decreases. This causes the ...
35 falcon industrie 8.10 general test and fault finding chart 1 check electrical supply - c.H. Water pressure and frost protection is led5 on? Put main switch to on ch selector to summer “ ” position d.H.W. Taps closed is 230v present across terminals x1-1 x1-2? Check and if necessary replace 2a fus...
36 industrie falcon chart 2 check domestic hot water operation chart 3 check central heating operation check and if necessary replace dhw sensor no is led3 on? Open dhw taps dhw flow rate at least 2,5 litre/min? Check cold water inlet pressure check and if necessary replace flow sensor is led4 flash...
37 falcon industrie chart 4 check fan/flue gas system chart 5 check d.H.W. And c.H. Modulation does fan run? Is relay ry100 switch on? No go to charts 2-3 no is 230v present across fan terminals? Yes check air pressure switch wiring connection in n.O. No check and if necessary replace air pressure s...
38 industrie falcon chart check ignition system is led1 light on? Does sparking start at burner? Does burner light? Yes is led2 on after 10 seconds? No yes go to chart 5 reset lockout yes does burner light now? Is flame present before lockout condition? No yes no check and if necessary replace safet...
39 falcon industrie 9. Electrical and functional scheme 9.01 main components layout on electronic boards jp01 on = delay between shutdown and re-ignition disabled jp01 off = delay between shutdown and re-ignition enabled jp02: jumper on for natural gas jumper on for lpg jp03 on = max temperature d.H...
40 industrie falcon 9.02 general wiring diagram key 16 fan 32 central heating pump 34 central heating flow temperature sensor 42 domestic hot water flow temperature sensor 43 air pressure switch 44 gas valve 49 safety thermostat 50 central heating limit thermostat 62 time clock (option) fig. 41 key ...
41 falcon industrie fig. 41 10. User instructions the boiler is designed for use with two types of gas: natural gas ng or propane (lpg). The type of gas can be selected when purchasing the boiler or the appliance can be converted later on site by a competent person. It operates with technologically ...
42 industrie falcon frost protection in cold weather the boiler may appear to run when there is no demand for heating (i.E. Clocks or room thermostats turned off). This is due to the central heating sensor going into frost protection mode. Once the boiler has reached 14 ° c or more it will close dow...
43 falcon industrie over ride by pressing the over ride button ( e ) the timer programme is over ridden ie, if programme is in off time it will come on and if in on time will go off. The timer will revert back to it set programme on reaching the next on or off time. When the programme is on over rid...
Po box 3774, sutton coldfield, west midlands b76 8dh tel: 0121 352 3200 fax: 0121 352 3210 all specifications subject to change phone numbers: installer service engineer because of our constant endeavour for improvement details may vary slightly from those quoted in these instructions. Please note -...
