Ferroli Falcon II Installation, Servicing And User Instructions Manual
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Ferroli Falcon II 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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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
INSTALLATION,
SERVICING AND
USER INSTRUCTIONS
G.C. NO: 47-267-24
FALCON II

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Summary of Contents for Ferroli Falcon II

  • Page 1 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 INSTALLATION, SERVICING AND USER INSTRUCTIONS G.C. NO: 47-267-24 FALCON II...

  • Page 2: Table Of Contents

    FALCON II IMPORTANT Your "benchmark" Installation, Commissioning and Service Record Log Book is enclosed in the last pages of this manual. “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: Description

    FALCON II 1. DESCRIPTION 1.01 Introduction The Falcon II 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 4: Technical And Dimensional Characteristics

    FALCON II 2. TECHNICAL AND DIMENSIONAL CHARACTERISTICS 2.01 Technical information Falcon II 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 connections Fig.
  • Page 5 FALCON II Technical Data 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...
  • Page 6 FALCON II 2.02 Boiler main components 2.03 Boiler water fl ow diagram FLUE FERROLI GRUNDFOS 85 44 AUTO Fig. 3 OVER RIDE C.H. D.H.W. D.H.W. C.H. Fig. 2 Domestic hot water flow * For use with flue gas analyser temperature sensor...
  • Page 7 FALCON II 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 and 5 and see paragraph 5.04 page 23). The diagrams indicate the variation in heat output to the water as burner working pressure is varied.
  • Page 8 FALCON II SAFETY VALVE SETTING (bar) SIZING OF ADDITIONAL EXPANSION VESSELS: VESSEL CHARGE Deduct from the value given in the table the 10 litre PRESSURE (bar) vessel supplied. INITIAL SYSTEM PRESSURE (bar) TOTAL WATER Note: EXPANSION VESSEL VOLUME (litres) CONTENT of SYSTEM 1.

  • Page 9: Installation Details

    FALCON II 3.0 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 10 FALCON II 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 11 FALCON II 5 min. 5 min. 50 mm CLEARANCES: * 600mm minimum clearance for ser- 600* min. vicing access Fig. 10 Terminal Position Fig. 11 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...
  • Page 12 FALCON II 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 13 FALCON II 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. 13). N.B.: the diameter of the hole is stamped on the restrictor Boiler is fi...
  • Page 14 FALCON II 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 Concentric at the joints makes this an extremely easy and safe Vertical option.
  • Page 15 FALCON II Notes on concentric horizontal installa- tion To locate the centre of the hole for passing the pipes through the wall, refer to fig. 12. Bear in mind that the two concentric pipes must slope Between downwards away from the boiler at a rate of 10-60mm about 3 mm/m to avoid rainwater entering the boiler.
  • Page 16 FALCON II 3.04 Top Outlet: Two Pipe Flue System 3.04.1 Two pipe connection Ø80 Ø80 Two separate ducts Ø80 for air intake and flue gas FLUE discharge can be directly connected to the boiler. mount the separate outlet kit "1". Insert blanking plate 2 in remaining air intake Fig.
  • Page 17 FALCON II 3.04.2 (continued) REDUCTION REDUCTION Tab. 1 - Pipes and FLUE FLUE fi ttings reduction table Description Dscription Male-female flue/Air pipe Horizontal 1 m - Ø 80 flue terminal Ø 80 mm Female-female bend Air intake 45° Ø 80 m terminal Ø...
  • Page 18 FALCON II For further accessories please refer to: "Flue system manual for room sealed boiler" Example of calculation for wall inlet/outlet with 2 pipe system maximum total fl ue length: 50 metres Attention: 13 m 13 m Remove the fl ue diaphragm. The fl...
  • Page 19 FALCON II 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 20 FALCON II When the boiler is connected to an electricity main, it is essential TO OBSERVE CORRECT POLARITIES (LIVE: brown cable, NEUTRAL: blue cable, EARTH: yellow-green cable). All wiring must conform to current I.E.E. regulations. 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.

  • Page 21: Commissioning And Testing

    FALCON II 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 first time check: • that the gate valves between the boiler and central heating system are open; •...

  • Page 22: Adjustment And Gas Conversion

    FALCON II hot water tap is turned on and off. • Check that the domestic hot water flow and T correspond to the table. Do not rely on empirical measurements. Temperature should be measured using thermometers as near as possible to the boiler, bearing in mind the heat loss from the pipes.
  • Page 23 FALCON II 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 Fig. 22 P5 = Minimum gas pressure adjustment 5.04 Adjusting maximum output for central heating system (fig. 22) This adjustment must be carried out electronically using the “P3”...

  • Page 24: Maintenance And Cleaning

    FALCON II 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 25 FALCON II 16. Clean heat exchanger with a soft brush. 17. Re-assemble baffle, flue hood and fan assembly, secure with screws previously removed. 18. Refit burner assembly and burner rail. 19. Reconnect ignition and flame rectification leads. 20. Reconnect gas union and tighten. 21.

  • Page 26: Replacement Of Parts

    FALCON II 7.0 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.
  • Page 27 FALCON II Gas valve (fig. 26) 7.05 • 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") • Disconnect plastic tube "C" •...
  • Page 28 FALCON II Removal of burner (fig. 29) 7.10 • 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 29 FALCON II 7.14 Spark or fl ame detection electrode (fig. 31) • Isolate gas and electricity supply • Remove outer case (two screws bottom rear corners) • Open room sealed compartment and combustion chamber • Identify electrode from fig. 31 •...
  • Page 30 FALCON II Pump (fig. 33) 7.16 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 31: Fault Finding

    FALCON II 8.0 FAULT FINDING Before beginning any fault finding ensure that gas, water and electricity are available. WARNING: DO NOT link any terminals on block X10 or X11 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 32 FALCON II In order, the five lights indicate: 1 Boiler On Indicate 2 Boiler Shut down warning 3 Domestic Hot Water circuit ON 4 Central Heating standby (Flashing Light) Central Heating circuit ON (Permanent Light) 5 Insufficient pressure in Central Heating System (Flashing Light) Electric power supply ON (Permanent Light) Note: Always check for sufficient gas supply (20mbar inlet working pressure for NG and 37mbar for LPG).
  • Page 33 FALCON II 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. The wiring for each thermistor is colour coded red for C.H.
  • Page 34 FALCON II 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 35 FALCON II 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 36 FALCON II 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...
  • Page 37 FALCON II Chart 6 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 38: Electrical And Functional Scheme

    FALCON II 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 39 FALCON II 9.02 General wiring diagram Blue Blue Blue Blue Blue Blue Blue Blue Blue...

  • Page 40: User Instructions

    FALCON II 10. USER INSTRUCTIONS AUTO 12:31 OVER RIDE Fig. 36 KEY DESCRIPTION Switch OFF/ON/RESET Burner on indicator Central heating flow temperature regulation Boiler shut down warning D.H.W. temperature Domestic hot water circuit on regulation Central heating stand-by Water pressure gauge Central heating circuit on Insufficient pressure in central heating system Time clock...
  • Page 41 FALCON II Boiler lock out In the event of the red lockout light ( ) coming on, the on/off/reset switch (A) should be turned clockwise against the spring tension to the reset position and released (this will put the boiler into three minute delay if in the heating mode).
  • Page 42 FALCON II 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 43 FALCON II...

  • Page 44: Benchmark

    2 6 7 BENCHMARK No. Please add the first 4 digits of the Boiler serial No to complete the BENCHMARK No. GAS BOILER COMMISSIONING CHECKLIST C O L L E C T I V E M A R K BOILER SERIAL No. NOTIFICATION No.

  • Page 45: Service Interval Record

    SIGNATURE SERVICE 10 SERVICE 9 DATE DATE ENGINEER NAME ENGINEER NAME COMPANY NAME COMPANY NAME TEL No. TEL No. CORGI ID CARD SERIAL No. CORGI ID CARD SERIAL No. COMMENTS COMMENTS SIGNATURE SIGNATURE FERROLI TECHNICAL HELPLINE - 08707 282 885...
  • Page 48 Phone numbers: Installer _______________________ Service Engineer ________________ BECAUSE OF OUR CONSTANT ENDEAVOUR FOR IMPROVEMENT DETAILS MAY VARY SLIGHTLY FROM THOSE QUOTED IN THESE INSTRUCTIONS. 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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