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Fer Falcon 47-26701 Installation, Servicing And User Instructions Manual

Copper wall-mounted combination, gasa fired boiler for central heating, and domestic hot water production
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INDUSTRIE
C
OPPER
G
F
AS
D
AND
F
A
AN
SSISTED
E
LECTRONIC
INSTALLATION,
SERVICING AND

USER INSTRUCTIONS

G.C. NO: 47-26701
W
-M
ALL
OUNTED
B
IRED
OILER FOR
H
W
OMESTIC
OT
, R
S
OOM
F
I
LAME
GNITION AND
FALCON
C
OMBINATION
C
H
ENTRAL
EATING
P
ATER
RODUCTION
C
EALED
OMPARTMENT
C
ONTROL
,
,
,

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Summary of Contents for Fer Falcon 47-26701

  • Page 1: User Instructions

    INDUSTRIE OPPER OUNTED OMBINATION IRED OILER FOR ENTRAL EATING OMESTIC ATER RODUCTION SSISTED EALED OMPARTMENT LECTRONIC LAME GNITION AND ONTROL INSTALLATION, SERVICING AND USER INSTRUCTIONS G.C. NO: 47-26701 FALCON...
  • Page 2 FALCON INDUSTRIE 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. Both should be recorded in your central heating log book.

  • Page 3: Table Of Contents

    FALCON INDUSTRIE 1. Description ............................. 4 2. Technical and dimensional characteristics ....................5 3. Installation Details ..........................10 4. Commissioning and testing ........................22 5. Adjustment and gas conversion ......................23 6. Maintenance and cleaning ........................25 7. Replacement of Parts ..........................27 8.

  • Page 4: Description

    FALCON INDUSTRIE 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 production.

  • Page 5: Technical And Dimensional Characteristics

    FALCON INDUSTRIE 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. Distance between connection Top view Boiler connections Fig.
  • Page 6 FALCON INDUSTRIE Technical Data Domestic hot Domestic hot Heat Boiler water Heat output water heat water circuit input contents MODEL input contents Litres Litres FALCON 23,3 25,8 11,5 23,3 Max. working Connections Expansion vessel Max. working pressure pressure hot central heating MODEL water circuit circuit...
  • Page 7 FALCON INDUSTRIE 2.02 Boiler main components 2.03 Boiler water flow diagram FLUE Fig. 3 7 85 44 9 136 C.H. D.H.W. D.H.W. C.H. AUTO RESET OVER RIDE °C °C Fig. 2 5 Room sealed compartment 29 Internal flue exit 82 Sensor electrode 7 Gas inlet 32 Central heating pump 84 Primary gas valve solenoid...
  • Page 8 FALCON INDUSTRIE 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 variation in heat output to the water as burner working pressure is varied.
  • Page 9 FALCON INDUSTRIE 2.06 Pump characteristics The pump head available for circulating the water is given in fig. 7. N.B. - The pump is factory set at position 3. The pump is a Grundfos type 15-50 UPS series. Grundfos Pump performance graph Note - Minimum flow through boiler heat exchanger at any time should not fall below 6 litres per minute.

  • Page 10: Installation Details

    FALCON INDUSTRIE 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, current I.E.E. Regulations and the byelaws of the Local Water Undertaking.
  • Page 11 FALCON INDUSTRIE 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).
  • Page 12 FALCON INDUSTRIE CLEARANCES: 5 min. 5 min. 50 mm * 600mm minimum clearance for servicing access 600* min. Fig. 11 Terminal Position Fig. 12 POSITION MINIMUM SPACING Directly below an openable window, air vent, or any other ventilation opening Below gutters, soil pipes or drainpipes Below Eaves Below a Balcony From vertical drainpipes or soilpipes...
  • Page 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 in the fig.
  • Page 14 FALCON INDUSTRIE 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 that it is correctly positioned (see fig.
  • Page 15 FALCON INDUSTRIE 3.03 Top Outlet Concentric Flue Connection 3.03.1 Vertical concentric connection A vertical connector can be supplied for vertical discharge with concentric pipes. The simple mounting and use of double lip gaskets at the Concentric joints makes this an extremely easy and safe option. Vertical Connector Fig.
  • Page 16 FALCON INDUSTRIE 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 entering the boiler.
  • Page 17 FALCON INDUSTRIE 3.04 Top Outlet: Two Pipe Flue System 3.04.1 Two pipe connection Insert blanking plate 2 Ø80 Ø80 in remaining air intake Two separate ducts Ø80 for air intake and flue FLUE gas discharge can be directly connected to the boiler.
  • Page 18 FALCON INDUSTRIE 3.04.2 (continued) Reduction Reduction Tab. 1 - Pipes and Flue Flue fittings reduction table Description Description Ø Ø Ø...
  • Page 19 FALCON INDUSTRIE For further accessories please refer to: Attention: flow resistance (reduction) equivalent in- "Flue system manual for room sealed boiler" cluded between 38 and 48 (see table on page 14) Remove the flue diaphragm. Example of calculation for wall inlet/outlet The flue and air pipes must have an inclination with 2 pipe system downward equal to 3% from boiler to outside.
  • Page 20 FALCON INDUSTRIE 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 will not be hazardous to occupants and passers-by or cause damage to external electric components or wiring.
  • Page 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 contacts.

  • Page 22: Commissioning And Testing

    FALCON INDUSTRIE 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; •...

  • Page 23: Adjustment And Gas Conversion

    FALCON INDUSTRIE Temperature should be measured using thermometers as near as possible to the boiler, bearing in mind the heat loss from the pipes. • Check that the gas valve modulates correctly both during the central heating phase and the domestic hot water production phase.
  • Page 24 FALCON INDUSTRIE 5.03 Adjustment potentiometers P1 = C.H. temperature adjustment P2 = D.H.W. temperature adjustment P3 = C.H. output adjustment P4 = Ignition gas pressure adjustment P5 = Factory set - Don't touch Fig. 25 5.04 Adjusting maximum output for central heating system (fig. 25) This adjustment must be carried out electronically using the “P3”...

  • Page 25: Maintenance And Cleaning

    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 the case, bring it back to this value. •...
  • Page 26 FALCON INDUSTRIE 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.

  • Page 27: Replacement Of Parts

    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 both the central heating or domestic hot water circuits of the boiler only.
  • Page 28 FALCON INDUSTRIE 7.05 Gas valve (fig. 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") •...
  • Page 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" •...
  • Page 30 FALCON INDUSTRIE 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 electrode •...
  • Page 31 FALCON INDUSTRIE 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 •...

  • Page 32: Fault Finding

    FALCON INDUSTRIE 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-by mode i.
  • Page 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 sufficient gas supply (20mbar inlet working pressure for NG and 37mbar for LPG).
  • Page 34 FALCON INDUSTRIE 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 PCB to reduce the voltage to the modureg, in turn reducing the burner pressure.
  • Page 35 FALCON INDUSTRIE 8.10 General test and fault finding Chart 1 Check electrical supply - C.H. water pressure and frost protection Chek the following carefully before starting • Gas supply is turned on, is adequate and purged • Electricity supply is turned on •...
  • Page 36 FALCON INDUSTRIE Chart 2 Check Domestic Hot Water operation Open DHW taps DHW flow rate at least 2,5 litre/min? Check cold water inlet pressure Check and if necessary Is LED3 on? replace DHW Sensor Check if water filter is clean Check and if necessary replace Flow Sensor Is LED4 flashing?
  • Page 37 FALCON INDUSTRIE Chart 4 Check fan/flue gas system Does fan run? Is air pressure switch activated? Is relay RY100 switch ON? Go to chart 5 Differential air pressure across the air pressure Go to charts 2-3 switch is greater than 180 Pascal? Check and if necessary replace...
  • Page 38 FALCON INDUSTRIE Chart Check ignition system Is LED1 light on? Is LED2 on Does sparking start without at burner? the boiler sparking Does burner light? Go to chart 5 Re-check air pressure switch Check and if necessary Is LED2 on replace safety thermostat after 10 seconds? Check electrodes and...

  • Page 39: Electrical And Functional Scheme

    FALCON INDUSTRIE 9. ELECTRICAL AND FUNCTIONAL SCHEME 9.01 Main components layout on electronic boards Potentiometer adjustment P1 = Central heating flow temperature adjustment P2 = Domestic hot water temperature adjustment P3 = Central heating flow output adjustment P4 = Ignition gas pressure adjustment P5 = Minimum adjustment pressure MV1 MV2 MV3 MV4 JP03...
  • Page 40 FALCON INDUSTRIE 9.02 General wiring diagram...

  • Page 41: User Instructions

    FALCON INDUSTRIE 10. USER INSTRUCTIONS Fig. 41 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 advanced systems such as electronic adjustment, safety and control devices.
  • Page 42 FALCON INDUSTRIE 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 either the temperature again falls below 7°C or the clock or room thermostat is turned on.
  • Page 43 FALCON INDUSTRIE Time Clock A 24 hour time clock is fitted to the boiler to control the central heating, this will come into operation when the selector switch is turned to the position marked “heating timed and hot water”. Slide switch: set clock - auto - set programme AUTO AUTO Display.
  • Page 44 Phone numbers: Installer Service Engineer BECAUSE OF OUR CONSTANT ENDEAVOUR FOR IMPROVEMENT DETAILS MAY VARY SLIGHTLY FROM THOSE QUOTED IN THESE INSTRUCTIONS. INDUSTRIE ALL SPECIFICATIONS SUBJECT TO CHANGE Please note - to avoid incurring unnecessary expense, in the event of a boiler shut down, check this in not caused by lack of electricity supply, gas supply or low water pressure before calling our Customer Service Helpline.

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