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- Installation, Servicing And User Instructions Manual
Ferroli Falcon Installation, Servicing And User Instructions Manual - Falcon
30
FALCON
7.12
Spark or fl ame detect electrode (fi g. 34)
• Isolate gas and electricity supply
• Remove outer case (two screws bottom rear corners)
• Open room sealed compartment and combustion
chamber
• Identify electrode from fi g. 34
• Unplug electrical connection "A" from sensing
electrode
• Remove fi xing screw and remove fl ame detect
electrode
• Remove the two fi xing screw from spark electrode
plate and remove it.
7.13
D.H.W. fl owmeter
• Isolate electricity and water supplies
• Open a hot water tap to release water pressure from the
domestic side of the heat exchanger, close tap.
• Remove outer case (two screws bottom rear corners).
• Remove two screws from control panel and tilt forward
• Take off protective cover from main PCB and unplug fl ow
meter lead from terminal X6
• Place a piece of cloth or some other absorbent material over
rear of control panel to catch any drops of water that may be
released when removing the fl ow meter
• Using a 24mm open ended spanner, undo fl ow meter unions
"A" and "B" taking care not to twist the copper tubing (access
through base panel).
• Remove fl ow meter, check + clean fi lter + restrictor + fi t to
new fl ow meter.
• Reassemble in reverse order.
Spark
A
Flame
detect
A
B
Fig. 34
Fig. 35a
37
39
38
38
Key
37
Cold water inlet fi lter
38
Gasket
39
Cold water fl ow limiter
Take care on correct position of
components as reported in fi g. 35b
Fig. 35b
Summary of Falcon
Page 1
Appr. Nr. B 9709a - ce n° 0063 at 4967 installation, servicing and user instructions g.C. No: 47-26701 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 f lame i gn...
Page 2: Falcon
2 falcon ce mark ce mark documents that the ferroli gas appliances comply with the requirement contained in european directives applicable to them. In particular, the appliances comply with the following cee directives and the technical specifi cations provided from them: • gas appliances directive ...
Page 3: Falcon
3 falcon index 1. Description ..................................................................................................................................... 4 2. Technical and dimensional characteristics....................................................................... 5 3. Installation ...
Page 4: Falcon
4 falcon 1. Description 1.01 introduction the falcon is defi ned 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 fi red heat generator for central heating and domestic hot water productio...
Page 5: Falcon
5 falcon 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 heating fl ow...
Page 6: Falcon
6 falcon n.B. - the gas pressures at the burner and gas fl ows 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 fi gures 4 and 5). During domestic ...
Page 7: Falcon
7 falcon 2.03 boiler water fl ow diagram out i min air in air in flue out c.H. Out d.H.W. Out gas in d.H.W. In c.H. In fig. 3 2.02 boiler main components fig. 2 key 5 room sealed compartment 7 gas inlet 8 domestic hot water outlet 9 domestic hot water inlet 10 central heating fl ow outlet 11 central...
Page 8: Falcon
8 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 (fi g. 4, 5 and see paragraph 5.04 page 24). The diagrams indicate the variation...
Page 9: Falcon
9 falcon 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 fi tted to...
Page 10: Falcon
10 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 practice, curr...
Page 11: Falcon
11 falcon 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 underfl oor spaces). Drain tap...
Page 12: Falcon
12 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 external corn...
Page 13: Falcon
13 falcon 3.01 drilling template (top flue application) select suitable mounting position for boiler, using the template mark fl ue outlet and boiler mounting points. Drill two 10mm holes 90mm deep to accept the wall plugs, fi t wall plugs. Fit two special wall plugs on the wall as described in the ...
Page 14: Falcon
14 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 fl ue restrictor required. Before inserting the fl ue gas duct in the boiler, check that the restrictor fi tted is correct and that it...
Page 15: Falcon
15 falcon a 90° bend (fi g. 16) is supplied for the horizontal connection of air and fl ue 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=100 Ø2=60 ...
Page 16: Falcon
16 falcon fig. 17 notes on concentric horizontal installation to locate the centre of the hole for passing the pipes through the wall, refer to fi g. 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 entering the boi...
Page 17: Falcon
17 falcon fig. 19 3.04 top outlet: two pipe flue system 3.04.1 two pipe connection two separate ducts Ø80 for air intake and fl ue gas discharge can be directly connected to the boiler. Fit separate air intake plate. Connect fl ue duct to central hole Ø80 and air duct to left or right air intake hol...
Page 18: Falcon
18 falcon 3.04.2 (continued) tab. 1 - pipes and fi ttings reduction table air flue v ertical horizontal v ertical horizontal description male-female flue Ø80 female-female bend 45° Ø80 female-female bend 90° Ø80 male-female bend 90° Ø80 pipe fitting m/m/f Ø80 with inspecting plug+trap for condensate...
Page 19: Falcon
19 falcon for further accessories please refer to: "flue system manual for room sealed boiler" attention: fl ow resistance (reduction) equivalent included between 38 and 48 (see table on page 14) remove the fl ue diaphragm. The fl ue and air pipes must have an inclination down- ward equal to 3% from...
Page 20: Falcon
20 falcon 3.05 connecting the central heating and domestic hot water circuits connect to the relevant connections as indicated in fi g. 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 will not ...
Page 21: Falcon
21 falcon 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 contacts. The s...
Page 22: Falcon
22 falcon 4. Commissioning and testing 4.01 checks to be carried out before starting up for the fi rst time when starting the boiler up for the fi rst time check: • that the gate valves between the boiler and central heating systems are open; • that the central heating system is fi lled and vented; ...
Page 23: Falcon
23 falcon 5. Adjustment and gas conversion 5.01 adjusting the pressure and fl ow rate to the main burner this boiler operates on the fl ame modulation principle. It has two fi xed pressure values, minimum and maximum, which must be as shown in the table (pages 6), whichever type of gas is used. Note...
Page 24: Falcon
24 falcon 5.04 adjusting maximum output for central heating system (fi g. 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. Rotate the te...
Page 25: Falcon
25 falcon 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 the case, ...
Page 26: Falcon
26 falcon 18. Refi t burner assembly and burner rail. 19. Reconnect ignition and fl ame rectifi cation leads. 20. Reconnect gas union and tighten. 21. Refi t combustion chamber cover, secure with screws. 22. Examine seals on room sealed cover refi t cover and secure with screws. 23. Turn on gas and ...
Page 27: Falcon
27 falcon 7.04 remove and re-presurising of c.H. Expansion vessel (fi g. 28) • refer to 7.01 a, b • isolate electricity and water supplies • loosen the "a" connections to expansion vessel from the bottom of the boiler • remove "b" screws from the top of the boiler • remove the expansion vessel from ...
Page 28: Falcon
28 falcon 7.05 gas valve (fi g. 29) • isolate gas and electricity supplies • remove outer case (two screws bottom rear corners) • remove the two securing screws and lower control panel • disconnect electrical connections from valve ("a", "b") • disconnect plastic tube "c" • loosen the connection "d"...
Page 29: Falcon
29 falcon 7.08 removal of burner (fi g. 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 to the b...
Page 30: Falcon
30 falcon 7.12 spark or fl ame detect electrode (fi g. 34) • isolate gas and electricity supply • remove outer case (two screws bottom rear corners) • open room sealed compartment and combustion chamber • identify electrode from fi g. 34 • unplug electrical connection "a" from sensing electrode • re...
Page 31: Falcon
31 falcon 7.14 pump (fi g. 36) replacement of pump head • isolate electricity and fl ow 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 the pump lead "a" from...
Page 32: Falcon
32 falcon 8. Fault finding before beginning any fault fi nding 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-by mode i...
Page 33: Falcon
33 falcon in order, the fi ve 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 suffi cie...
Page 34: Falcon
34 falcon 8.04 temperature sensors (thermistors) identical, but individual, negative temperature co-effi cient (ntc) thermistors are fi tted 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 pcb to r...
Page 35: Falcon
35 falcon 8.10 general test and fault fi nding 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 fuse yes is ...
Page 36: Falcon
36 falcon chart 2 check domestic hot water 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 flashing? No is relay ry100 switch on? No yes check if ...
Page 37: Falcon
37 falcon chart 4 check fan/fl ue gas system 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 switch no check and if necessary replace fan yes is...
Page 38: Falcon
38 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 safety thermost...
Page 39: Falcon
39 falcon 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 jp04 on = max temperature d.H.W. 62°c jp04 off= max temperature d.H.W. 55°c (standard) p.C.B. Main board mf02 jp02 x8 jp01 4...
Page 40: Falcon
40 falcon key 16 fan 32 ce n tr al he ati n g pump 3 4 ce n tr al he ati n g fl ow temper ature s en so r 42 d ome sti c ho t w ater fl ow temper ature s en so r 4 3 a ir pre ss ure sw it ch 44 g as v al ve 4 9 sa fet y therm os ta t 50 ce n tr al he ati n g limit therm os ta t 6 2 t ime c lo ck fig...
Page 41: Falcon
41 falcon ignition control 72 43 49 44 mv1 16 x2-3 x2-4 x2-1 x2-2 x1-1 x1-2 x1-8 p4 h1 h2 81 82 x10-1 x10-2 p5 p2 p3 p1 test switch x5-1 x5-2 l1 l2 l3 l4 l5 x7-1 x7-2 42 x7-7 x7-8 34 x7-9 x7-10 out x6-4 x6-2 x6-1 x1-3 x7-1 x7-2 x3 x5 x4 x1-7 x1-6 x1-5 x3-1 x3-2 x3-3 ry01 x2-3 32 x2-1 x4-2 62 x4-1 x3...
Page 42: Falcon
42 falcon fig. 41 1 2 3 key 1 = d.H.W. Temperature regulation (set on normal position) 2 = central heating flow temperature regulation 3 = switch off/on/reset normal bar - electric power supply - domestic hot water circuit on - central heating circuit on - central heating stand-by - insufficient pre...
Page 43: Falcon
43 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 down until eith...
Page 44: Falcon
44 falcon 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 ride the sign w...
Page 48
Po box 3774, sutton coldfi eld, west midlands b76 8dh tel: 08707 282 885 fax: 08707 282 886 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 ...