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Fer FALCON II Installation, Servicing & User Instructions

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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C
OPPER
G
AS
AND
F
AN
E
LECTRONIC
INSTALLATION,
SERVICING AND

USER INSTRUCTIONS

G.C. NO: 47-267-24
W
-M
ALL
F
B
IRED
OILER FOR
D
H
OMESTIC
A
, R
SSISTED
OOM
F
LAME
FALCON II
C
OUNTED
OMBINATION
C
ENTRAL
W
P
OT
ATER
RODUCTION
S
C
EALED
OMPARTMENT
I
GNITION AND
,
H
EATING
,
,
C
ONTROL

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Summary of Contents for Fer FALCON II

  • Page 1: User Instructions

    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: 47-267-24 FALCON II...

  • Page 2: Table Of Contents

    You can check the installer's CORGI registration by calling CORGI on 01256 372300". FER is a member of the Benchmark initiative and fully supports the aims of the programme. Benchmark has been introduced to improve the standards of installation and commissioning of central heating systems in the UK and to encourage the regular servicing of all central heating systems to ensure safety and efficiency.

  • Page 3: 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 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).
  • Page 6 FALCON II 2.02 Boiler main components 2.03 Boiler water flow 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).
  • 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 PRESSURE (bar) litre vessel supplied. INITIAL SYSTEM PRESSURE (bar) Note: TOTAL WATER EXPANSION VESSEL VOLUME (litres) CONTENT of SYSTEM Fill C.H.

  • Page 9: Installation Details

    Location of Boiler The installation of the Falcon II must be on a suitable non-combustible load bearing wall which will provide an adequate fixing for the boiler mounting bracket assembly. The location should be in an area where the water pipes will not be subjected to frost conditions.
  • 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 servi- 600* min. cing access Fig. 10 Terminal Position Fig. 11 POSITION MINIMUM SPACING Directly below an openable window, air vent, or any other ventilation opening...
  • 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.
  • 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 at the Concentric joints makes this an extremely easy and safe option.
  • Page 15 FALCON II Notes on concentric horizontal installation 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 downwards away from the boiler at a rate of about 3 mm/m to avoid rainwater entering the boiler.
  • Page 16 "2" in remaining air intake. A varied selection of accessories for two pipe systems are available from FER (ref. to page 17). Before installing your system please check via calculation table at 3.04.2 you are not exceeding the maximum permissible length for the appliance.
  • Page 17 FALCON II 3.04.2 (continued) REDUCTION REDUCTION Tab. 1 - Pipes and FLUE FLUE fittings 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 flue length: 50 metres Attention: 13 m 13 m Remove the flue diaphragm.
  • 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 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. Note - When connecting a room thermostat or external timer, do not link the power supply of these devices to the switching contacts.

  • Page 21: Commissioning And Testing

    FALCON II 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 system are open;...

  • Page 22: Adjustment And Gas Conversion

    FALCON II • 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 Customer Technical Service Helpline. 5.09 Gas conversion The following adjustment and conversion operations must be carried out by competent personnel. FER Limited accepts no liability for damage to property or personal injury resulting from tampering with the boiler by unauthorised persons.

  • 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 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. Refit combustion chamber cover, secure with screws.

  • 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 7.05 Gas valve (fig. 26) • 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 7.10 Removal of burner (fig. 29) • 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 flame 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 • Unplug electrical connection "A" from sensing electrode •...
  • Page 30 FALCON II 7.16 Pump (fig. 33) 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.
  • Page 34 FALCON II 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 35 FALCON II Chart 2 Open DHW taps Check Domestic Hot Water operation Open DHW taps DHW flow rate at least 2,5 litre/min? Check cold water DHW flow rate at inlet pressure least 2,5 litre/min? Check and if necessary Is LED3 on?
  • Page 36 FALCON II 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...
  • 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...

  • 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...
  • Page 39 FALCON II 9.02 General wiring diagram...

  • Page 40: User Instructions

    FALCON II 10. USER INSTRUCTIONS AUTO 12:31 OVER RIDE Fig. 36 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 (Flashing light) Water pressure gauge...
  • 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). If the lockout light ( ) illuminates repeatedly, contact an approved Férroli service engineer.
  • 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...
  • Page 44 Should you require help with any difficulties call our Technical Service Helpline on 08707 282 885 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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