Ferroli FALCON Installation, Servicing And User Instructions Manual

Copper wall-mounted combination, gas fired boiler for central heating and domestic hot water production, fan assisted, room sealed compartment, electronic flame ignition and control

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OPPER

OUNTED

OMBIN TION

IRED

OILER FOR

ENTR L

E TING

OMESTIC

TER

RODUCTION

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SSISTED

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OMP RTMENT

LECTRONIC

L ME

GNITION

ONTROL

INSTALLATION,

SERVICING AND

USER INSTRUCTIONS

G.C. NO: 47-26701

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Summary of Contents for Ferroli FALCON

Page 1 OPPER OUNTED OMBIN TION IRED OILER FOR ENTR L E TING OMESTIC RODUCTION SSISTED E LED OMP RTMENT LECTRONIC L ME GNITION ONTROL INSTALLATION, SERVICING AND USER INSTRUCTIONS G.C. NO: 47-26701...
Page 2 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: •...
Page 4 1.01 Introduction Falcon is d ﬁn d as a “room s al d” combination boil r, all air r quir d for combustion is tak n from outsid t room in w ic it is install d. It is a n w ig p rformanc gas ﬁr d...
Page 5 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. AUTO RESET OVER RIDE istance between connection op view Fig. 1...
Page 6 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...
Page 7 2.02 Boiler mai om o e t 2.03 Boiler water ﬂ ow diagram FLUE STEP 7 85 44 9 157 63 145 189 AUTO RESET 12:31 C.H. D.H.W. D.H.W. C.H. OVER RIDE °C °C 91 A r test po nt Room sealed compartment entral eat n Reset s...
Page 8 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 in heat output to the water as burner working pressure is varied.
Page 9 .06 Pump ara eris i s The pump head available for circulating the ater is given in g..The pump is factory set at position . The pump is a Grundfos type 15 50 PS series. Gru dfos Pump performa e grap inimum o through boiler heat exchanger at any time...
Page 10 Gas Safety (Installation & Use) Regulations: 1996 In the interest of safety, it is t e la that a as a ian es are insta e y a o etent erson in a or an e ith the a o e e ations, i in ations...
Page 11 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...
Page 12 5 min. 5 min. 50 mm C A ANC S clearance or ervicing acce 600* min. Terminal Position POSITION MINIMUM SPACING Directly below an openable window, air vent, or any other ventilation opening elow g tter , oil pipe or drainpipe elow Eave elow a alcony vertical drainpipe or oilpipe...
Page 13 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 ﬁ...
Page 14 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...
Page 15 3.03 Top Outlet Concentric Flue Connection 3.03.1 Vertical concentric connection A ertical connector can be supplied for ertical discharge with concentric pipes. The si ple ounting and use of double lip gas ets at the Concentric oints a es this an e tre el eas and safe option. Vertical Connector 3.03.2 Horizontal concentric connection...
Page 16 125 mm concentric Maximum flue lenght permissible Vertical Horizontal* Vertical Horizontal* Falcon or horizontal lueing the re uction or a liance en or turret are alrea inclu e . Reduction for bend 100 mm concentric bend 90° 100 mm concentric bend 45°...
Page 17 For the restrictors please refer to cap. 3.02 to determinate the correct diaphragm. Check that the total ﬂ ow resistance calculated is less or equal to 48 metre the maximum permissible for Falcon.
Page 18 3.04.2 (continued) Reduction Reduction Flue Flue Tab. 1 - Pipes and ﬁ ttings reduction table Description Description Ø Ø Ø...
Page 19 For further accessories please refer to: Attention: ﬂ ow resistance (reduction) equivalent "Flue system manual for room sealed boiler" included between 38 and 48 (see table on page 14) Remove the ﬂ ue diaphragm. ample of calculation for all inlet outlet The ﬂ...
Page 20 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 be hazardous to occupants and passers-by or cause damage to external electric components or wiring.
Page 21 : 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. When connecting a room thermostat or external timer, do not link the power supply of these devices to the switching contacts.
Page 22 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 Temperature should be measured using thermometers as near as possible to the boiler, bearing in mind the heat loss from the pipes. • Chec that the gas valve modulates correctly both during the central heating phase and the domestic hot water production phase.
Page 24 Customer Technical ervice Helpline 9 Gas con ersion The followin adjustment and conversion operations must be carried out by competent personnel FERROLI Limited accepts no liability for dama e to property or personal injury resultin from tamperin with the boiler by unauthorised persons...
Page 25 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 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.
Page 27 7.01 Initia procedure he boiler is cold, electricity supply is isolated, and the as supply is turned off at the inlet of the boiler or replacement of parts where water connections are bro en, it will be necessary to isolate and drain either or both the central heatin or domestic hot water circuits of the boiler only he cold water mains inlet is isolated at the inlet coc...
Page 28 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" •...
Page 29 7.08 Removal of burner • Isolate as and electricity supplies • Remove outer case two screws bottom rear corners • Remove room sealed cover • Disconnect i nition and flame rectification leads "A" • undo as rail union "B" • Undo two screws securin the burner assembly to the boiler combustion chamber "D"...
Page 30 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 •...
Page 31 7.14 Pump Replacement of pump head • Isolate electricity and ﬂow and return pipes • Remove casin two screws bottom rear corners • Remove the two securin screws and lower control panel • Release pressure from boiler via pressure relief valve •...
Page 32 Before beginning any fault ﬁ nding ensure that gas, water and electricity are available. WARNING lin any ter inals on bloc as this will da age the B beyond re air. 8.01 Operating Sequence ith the ower established the boiler is in its stand by ode i.
Page 33 In order, the ﬁ ve lights indicate: ains electricit on lo voltage on eter o erated controls, roo ther ostat cloc and te erat re reg lator calling aiting ti e a ro i atel three in tes ater ress re s itch - WARNING Al a s chec for s fﬁ...
Page 34 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 reduce the voltage to the modureg, in turn reducing the burner pressure.
Page 35 8.10 General test and fault ﬁ nding 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 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? Check and if necessary...
Page 37 Chart 4 Check fan/ﬂ ue 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 Is 230V present across...
Page 38 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 Check and if necessary...
Page 39 9.01 Ma n omponents layout on ele tron boar s Potent ometer a ustment Lo at on P1 = entral heating ow te erature ad ust ent ain board P2 = Do esti hot water te erature ad ust ent ain board = entral heating ow out ut ad ust ent ain board...
Page 40 9.02 General wiring diagram MF02...
Page 41 9.03 Functional ﬂ ow diagram (MF02 + S4562DM1006) X1-1 X1-2 Main Board Reset X4-2 X4-1 RY01 X2-3 X2-1 230V AC Transformer 24V AC X7-1 X7-2 X10-1 X10-2 JP01 JP02 JP04 Test Switch X3-1 X3-4 X1-7 X1-3 Ignition RY02 0 - 6V X3-2 control X7-1...
Page 42 Normal - Electric power supply - Domestic hot water circuit on AUTO RESET - Central heating circuit on 12:31 OVER RIDE - Central heating stand-by °C °C - Insufficient pressure Front panel in central heating system 4 = Boiler shut down warning 1 = D.H.W.
Page 43 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 44 Cl ck A 24 m cl ck ﬁ w ll c m ma k “ ”. w c : cl ck a AUTO AUTO la . amm ON OFF 1..8 w ll w c ON f OFF a OFF f OVER RIDE A TO c l)
Page 48 P one nu e s: Installe Se i e En inee 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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47-26701