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
INSTALLATION,
SERVICING AND
USER INSTRUCTIONS
G.C. NO: 47-26701
Appr. nr. B 9709A - CE n° 0063 AT 4967
FALCON
3543272/0 - 09/00
FALCON
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. You can check to the CORGI registered by calling
CORGI on 01256 372300".
Ferroli 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 effi ciency.
Please see installation and servicing guidelines.
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 90/396
• Effi ciencies directive 92/42
• Low tension directive 73/23 (modifi ed from the 93/68)
• Electromagnetic compatibility directive 89/396 (modifi ed from the 93/68)
Year 2000 Compliance Declaration
We will guarantee that this products is altogether suitable for the data change in the Year 2000 (boiler has no
dependence from date change) and that no disruptions will occur which is caused by this product.
2
FALCON
INDEX
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. FAULT FINDING ............................................................................................................................... 32
9. ELECTRICAL AND FUNCTIONAL SCHEME ....................................................................................... 39
10. USER INSTRUCTIONS ....................................................................................................................... 42
3
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 production. A special feature of this boiler is its built-in electronic fl ame ignition and control unit making burner
operation completely automatic and safe. The main components are as follows:
• Copper heat exchanger consisting of three fi nned tubes specifi cally shaped for high effi ciency.
• There are three copper coils inserted in the three heating circuit tubes. These represent the domestic hot water heat
exchanger. Their shape and high exchange surface area enable the full output of the boiler to be absorbed.
• Ceramic fi bre insulated combustion chamber
• 12 stainless steel bladed burners specifi cally designed for this boiler.
• Fan for discharge of combustion products and intake of combustion air.
• Differential air pressure switch. For safety reasons, this ensures the burner ignites only when the fan is functioning correctly.
• Hermetically sealed compartment made from corrosion-resistant steel enclosing the above components.
• Combination gas safety valve with modulator, complete with pressure stabiliser.
• Flow meter giving the domestic hot water circuit precedence over the central heating circuit.
• Pressure relief valve for the central heating circuit set to open at 3 bar.
• Built-in Expansion vessel.
• Variable speed pump.
• Central heating fl ow temperature adjustment thermostat.
• Domestic hot water fl ow temperature adjustment thermostat.
• Central heating limit thermostat.
• Overheat safety thermostat.
• Electronic control unit for automatic fl ame ignition and control.
• Central heating low water pressure cut off switch.
• Domestic hot water fl ow temperature sensor.
• Central heating fl ow temperature sensor.
1.02 Instructions and regulations
Assembly, installation, fi rst start up and maintenance must be carried out by competent persons only, in accordance
with all current technical regulations and directives.
C.O.S.H.H.
Materials used in the manufacture of this appliance are non hazardous and no special precautions are required
when servicing.
Related Documents
This appliance must be installed strictly in accordance with these instructions.
The Gas Safety Regulations (Installations & Use) 1996.
The Local Building Regulations.
The Building Regulations.
The Buildings Standards (Scotland - Consolidated) Regulations.
British Standards Codes of Practice:
B.S. 7593 1992 TREATMENT OF WATER IN DOMESTIC HOT WATER CENTRAL HEATING SYSTEMS
B.S. 5546 1990 INSTALLATION OF HOT WATER SUPPLIES FOR DOMESTIC PURPOSES
B.S. 5440 PART 1 FLUES
B.S. 5440 PART 2 AIR SUPPLY
B.S. 5449 1990 FORCED CIRCULATION HOT WATER SYSTEMS
B.S. 6798 1987 INSTALLATION OF GAS FIRED HOT WATER BOILERS
B.S. 6891 1989 GAS INSTALLATIONS
B.S. 7671 1992 IEE WIRING REGULATIONS
B.S. 4814 1990 SPECIFICATION FOR EXPANSION VESSELS
B.S. 5482 1994 INSTALLATION OF LPG
Model Water Bye Laws
For Northern Ireland the rules in force apply
4
FALCON
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.
10 380 10
720
ON
60
70
50
RESET
OFF
123
80
40
0
4
bar
bar
CC
400
Distance between connection
36 95 60 60 95 54
187
710
AUTO
P
OI
x
x
OVER RIDE
-
+
P
R
187
360
400
71 120 120
89
195.5
2
1
3
Boiler connections
Key
1 - 3/4" central heating fl ow outlet
2 - 1/2" domestic hot water fl ow outlet
80
4
5
80 80
Top view
Fig. 1
3 - 1/2 “ gas inlet
4 - 1/2" domestic hot water inlet
5 - 3/4" central heating return inlet
5
FALCON
Technical Data
MODEL
Heat output
Heat
input
kW kW kW kW kW Litres Litres
FALCON 23,3 9,7 25,8 11,5 23,3 1,5 0,8
Domestic hot
water heat
input
Boiler water
contents
Domestic hot
water circuit
contents
Connections Expansion vessel
MODEL
12345Capacity
ШШШШШLitres bar bar bar
FALCON 3/4” 1/2” 1/2” 1/2” 3/4” 7 1 3 6
Main injectors (mm)
MODEL
FALCON 12x1,30 12x0,77 2,73 2,00 H. V K4105G
MODEL
FALCON 20 37 2,5 11,8 7,8 36,0 3
G20 - NG G31 - LPG G20 - NG G31 - LPG
ØØ m
Gas supply pressures Gas pressure at main burner for central heating
G20 - NG G31 - LPG
mbar mbar mbar mbar mbar mbar bar
Gas flow rates to main burners
for central heating
3
/h kg/h
G20 - NG G31 - LPG
minimum nominal minimum nominal
Pre-pressurising
value
Max. working
pressure
central heating
circuit
Max. working
pressure hot
water circuit
Gas valve
Ø 1/2”
Safety valve
Domestic hot water
MODEL
FALCON 11,1 9,5 11,8 36,0 IP44 38
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 hot water production, gas pressures to the burner must correspond to the maximum output
given in table for the type of gas.
Gas pressure must be adjusted during maximum draw-off of domestic hot water.
• Maximum working temperature for central heating fl ow: 85°C
• Maximum temperature of domestic hot water: 55°C, adjustable between 40°C and 55°C.
• Minimum domestic cold water pressure required for 95% heat input:
- Flow restrictor fi tted (standard) - 1,2 bar;
- Flow restrictor removed - 0,5 bar
6
production with
∆t 30°C
l/min. l/min. mbar mbar kg
Domestic hot water
production with
∆t 35°C
Max. working pressure
domestic hot water
G20 - NG G31 - LPG
Protection
level
Weight
FALCON
2.02 Boiler main components
5
28
90
132
49
22 82 81
20
21
114
34
42
STEP
STEP
OUTIN
4318729
AIR
IN
16
91
27
50
19
26
56
36
32
FLUE
OUT
AIR
IN
2.03 Boiler water fl ow diagram
10 14 8 84 7 85 44 9 136 11
157 63 98 145 189 190 62
AUTO
P
ON
60
70
50
RESET
OFF
321
80
40
bar
°C °C
4
0
bar
OI
12:31
4
x
x
OVER RIDE
-
+
P
R
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 heating return inlet
14 Safety valve
16 Fan
19 Combustion chamber
20 Burner assembly
21 Main injector
22 Burner
26 Combustion chamber insulation
27 Copper heat exchanger for central
heating and domestic hot water
28 Flue collector from heat exchanger
29 Internal fl ue exit
32 Central heating pump
OUT
I
MIN
Fig. 2
C.H.
OUT
D.H.W.
OUT
GASIND.H.W.
34 Central heating fl ow
temperature sensor
36 Automatic air vent valve
42 Domestic hot water fl ow
temperature sensor
43 Air pressure switch
44 Gas valve
49 Safety overheat thermostat
50 Central heating fl ow limit thermostat
56 Expansion vessel
62 Time clock
63 Central heating
temperature adjustment
81 Ignition electrode
82 Sensor electrode
84 Primary gas valve solenoid
85 Secondary gas valve solenoid
*90 Flue gas test point
Fig. 3
C.H.
IN
*91 Air test point
98 On/Off/Reset switch
114 Low water pressure cut off switch
132 Flue gas defl ector
136 Flow meter
145 Central heating pressure gauge
157 Domestic hot water temperature
adjustment
187 Flue diaphragm
189 Indication lack of fl ame
190 Indication lighted burner
* For use with fl ue gas analyser
IN
7
FALCON
b
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.
Adjusting boiler output to the actual requirements o f t he central heating system will minimise boiler cycling t hus saving fuel,
varying the output has virtually no effect on the effi ciency and combustion characteristics of the boiler.
Diagram of pressures
and outputs with Natural gas
14
13
12
11
10
9
8
mbar
7
6
5
4
3
2
kW
kcal/h
x 1000
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
8 9 10 11 12 13 14 15 16 17 18 19 20 21
Diagram of pressures and outputs
with LPG (Propane)
35
30
25
ar
20
m
15
10
9 1011121314151617
kW
kcal/h
X 1000
91011121314 18192015 16 178
18 19 20 21 22 23
Fig. 4
2.05 Domestic hot water variability characteristics
65
The temperature of the domestic hot water can
be varied from 40 to 55°C by adjusting the boiler
potentiometer.
Diagram of domestic hot water production
Fig. 6
C
°
60
55
50
Temperatura di erogazione sanitaria
45
40
39
Temperature of domestic hot water intake 15°C
Temp. entrata acqua sanitaria 15°C
Temperature of domestic hot water supply °C
0 345678910111213141516
Flow of domestic hot water L/min
Portata sanitaria dm /min.
3
Fig. 5
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
kcal/h
x1000
Boiler output exchanged kcal/hx1000
Potenza caldaia scambiata
8
FALCON
2.06 Pump characteristics
The pump head available for circulating the water is given in fi g. 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 fl ow through boiler heat exchanger at any time
should not fall below 6 litres per minute.
If the total volume of water in the system exceeds 40 litres an
additional expansion vessel must be fi tted to the central heating
return pipe.
1 2 3 Speed settings
A Boilers pressure drop
B Available pump head C.H.
Fig. 7
H
mbar x 100
Pressure loss diagram
8
7
6
5
4
3
2
1
3
m |h
Fig. 8
SAFETY VALVE
SETTING (bar)
SIZING OF ADDITIONAL EXPANSION VESSELS:
VESSEL CHARGE
Deduct from the value given in the table the 8 litre
PRESSURE (bar)
vessel supplied.
INITIAL SYSTEM
PRESSURE (bar)
TOTAL WATER
Note:
CONTENT of SYSTEM
1. Fill C.H. installation to min. 1.5 bar.
LITRES
2. Select the expansion vessel for a system
25 3.5 6.5 13.7 4.7 10.3 8.3
pressure of 2.0 bar.
50 7.0 12.9 27.5 9.5 20.6 16.5
75 10.5 19.4 41.3 14.2 30.9 24.8
3. Expansion vessel must be fi tted to central
100 14.0 25.9 55.1 19.0 41.2 33.1
heating return pipe.
125 17.5 32.4 68.9 23.7 51.5 41.3
4. The standard 7 litre expansion vessel is
150 21.0 38.8 82.6 28.5 61.8 49.6
charged to 1 bar.
175 24.5 45.3 96.4 33.2 72.1 57.9
5. The additional expansion vessel should be
200 28.0 51.8 110.2 38.0 82.4 66.2
For syst. volumes other than
charged to 1 bar.
those given above, mult. the syst.
0.140 0.259 0.551 0.190 0.412 0.33
volume by the factor across
0.5 1.0 1.5
1.0 1.5 2.0 1.5 2.0 2.0
EXPANSION VESSEL VOLUME (litres)
3.0
0
0.5 1.5 2.512
Q
9
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, current I.E.E. Regulations and
the byelaws of the Local Water Undertaking. Failure to comply with the Regulations may lead to prosecution; it is your
responsibility to ensure that the law is complied with.
N.B. For Northern Ireland the rules in force apply.
Important - If the boiler is to be fi tted in a timber framed building it should be fi tted in accordance with the Institute of Gas
Engineers document IGE/UP/7. If in doubt advice should be sought from the Local Supplier.
Location of Boiler
The installation of the Falcon must be on a suitable non-combustible load bearing wall which will provide an adequate
fi xing for the boiler mounting bracket assembly. The location should be in an area where the water pipes will not be
subjected to frost conditions. In siting the combination boiler the following limitations must be observed:
The combination boiler may be installed in any room or internal space, although particular attention is drawn
to the requirements of the current I.E.E. wiring regulations and in Scotland the electrical provisions of the
building regulations applicable in Scotland, with respect to the installation of the combination boiler in a room
or internal space containing a bath or shower.
Where a room sealed appliance is installed in a room c ontaining a b ath or shower any electrical switch or
appliance control utilising mains electricity must be situated so that it cannot be touched by a person using
the bath or shower.
Air Supply
The room or compartment in which the boiler is installed does not require a purpose provided vent when
using the standard concentric fl ue.
Flue System
The boiler allows the fl ue outlet to be taken from the rear of the boiler, from either side or vertically.
A standard fl ue length of 0.75 metres is provided. Alternative lengths of two or three metres can be supplied
(equivalent to wall thicknesses of up to 565, 1815 and 2815mm for rear fl ues, deduct 91mm plus distance from
side wall for side outlet fl ues). It is absolutely essential, to ensure that products of combustion discharging from the
terminal cannot re-enter the building, or enter any adjacent building, through ventilations, windows, doors, natural air
infi ltration or forced ventilation/air conditioning.
Gas Supply
If necessary the local Gas supplier should be consulted, at the installation planning stage, in order to establish
the availability of an adequate supply of gas.
An existing service pipe must not be used without prior consultation with the Local Gas supplier.
A gas meter can only be connected by the Local Gas supplier, or by a Local Gas suppliers Contractor.
Installation pipes should be fi tted in accordance with BS6891-1988.
Appliance inlet working pressure must be 20mbar MINIMUM, for NG and 37 mbar minimum for LPG.
Pipework from the meter to the combination boiler must be of an adequate size.
The boiler requires 2.73m3/h of natural gas, and 2,00 kg/h of LPG.
Do not use pipes of a smaller size than the combination boiler inlet gas connection.
The complete installation must be tested for gas soundness and purged as described in BS6981-1988. All pipework
must be adequately supported. An isolating gas valve is provided and should be fi tted on the boiler gas inlet. Please
wait 10 minutes when lighting from cold before checking gas rate. Gas pressures should be checked after the boiler has
operated for 10 minutes to reach thermal equilibrium.
Water System
Note - the boiler is designed for sealed systems only and must NOT be used on open vented systems.
10
FALCON
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 taps should be positioned at the lowest point of the system in accessible locations to permit
the whole system to be drained down. The drain taps should be in accordance with BS2879. Copper tubing to BS2871,
Part 1 is recommended for water carrying pipework. Pipework in horizontal runs should have a gradient where possible
to facilitate the removal of air. Ensure that the boiler heat exchanger is not a natural point for air collection. A typical
heating system with domestic hot water circuit is illustrated in fi g. 9.
Important - If thermostatic radiator vales are fi tted a bypass must be fi tted to ensure a minimum fl ow rate through the
boiler of 6 l/min. The bypass should be fi tted as far as possible from the boiler.
Make Up Water
Provision must be made for replacing water lost from the sealed system. Reference should be made to BS6798, for
methods of fi lling and making up sealed systems. There must be no direct connection between the boiler's central
heating system and the mains water supply. The use of mains water to charge and pressurise the system directly, is
conditional upon the Local Water Byelaws. Again any such connection must be disconnected after use. A typical
temporary fi lling loop is shown in fi g. 10.
Domestic Hot Water
Always fi t a scale reducer in "hard water areas" (18 clarke degrees or over)". A 15mm copper connection point on the
boiler for attaching to the main supply is provided. The maximum domestic water pressure for the inlet supply is 10 bar
(145 P.S.I.). If the cold mains supply exceeds 5 bar (72 P.S.I.), a water governor or pressure reducing valve must be
fi tted by the installer into the mains supply in an inconspicuous but accessible position preferable between 3 and 5 metres
(10-16ft) before the appliance. Such a valve must be approved by the Water Research Council.
Attention - is drawn to the Model Water Byelaws.
Fittings manufactured from duplex (alpha-beta) brass are not
acceptable for underground use and certain water undertakings
will not accept their use above ground.
Ensure all pipework is adequately supported
Gas
NOTE: A bypass must be fi tted as far as possible from
the boiler if thermostatic radiator valves are fitted
thoughout.
Key
1. Filling point C.H.
2. Temporary connection
3. Cold water supply Fig. 10
Cold water
Additional expansion
vessel C.H.
(if required)
Filling
point
C.H.
Bypass
Fig. 9
11
FALCON
CLEARANCES:
* 600mm minimum clearance for servicing access
Fig. 11
Terminal Position
400 5 min.5 min.
200 min.
100 min.860
720
360 50 mm
600* min.
Fig. 12
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 corners 100
G Above adjacent ground or balcony level 100
H From a surface facing the terminal 600
I Facing another terminal 1,200
J From opening (door/window) in carport into dwelling 1,200
K Vertically from a terminal on the same wall 300
L Horizontally from a terminal on the same wall 300
N Below carport 600
A Quinnel Barrat and Quinnel guard (part. No. C2) should be screwed to the wall centrally over the terminal, when
the terminal height is less than 2 m from fl oor level.
12
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 fi g. 13a. Fasten the wall bracket to the wall using an antitheft nut on the right side and a standard nut (M8) on the
left side. Mount the boiler on the wall bracket and fi x using an antitheft nut on the left side and a standard nut (M8) on
the right side. Using a core drill cut a 118mm diameter hole for the fl ue.
Fig. 13a
101.5
909 min 204.5 min
Ø 118
20
360
380
215
Ø3/4''Ø3/4'' Ø1/2''Ø1/2''Ø1/2''Ø1/2''
15 min
15 min
195.5
132456
5 min
1. CH fl ow
2. Safety Valve
219 min
400
200 min
3. Domestic hot water outlet
4. Gas supply
5. Domestic hot water inlet
6. CH return Fig. 13b
13
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 is correctly positioned (see fi g. 14).
N.B.: the diameter of the hole is stamped on
the restrictor
Boiler is fi tted with Ø45 restrictor as
standard
Holes Ø : 45 47 50
Ø
CHOICE OF R ESTRICTOR:
•With 2 pipe system:
- Calculate the total fl ow resistance of the air and
fl ue pipes in metres (cap. 3.08.2)
- utilise the table shown below to choose the more
suitable restrictor for the fl ow resistance calculated
RESTRICTOR FOR TWO PIPE SYSTEM
Total flow resistance
of flue system
Use restrictor
size
Fig. 14
• With concentric systems:
- Choose correct restrictor from table below.
RESTRICTOR FOR CONCENTRIC SYSTEM
Use
Flue lenght up to:
restrictor
size
minimum maximum mm
0 m 13 m 45
13 m 23 m 47
23 m 38 m 50
38 m 48 m No restrictor
14
Concentric
60 / 100
Concentric
80 / 125
1 bend + 1 meter 50 mm
1 bend + 3 meters No restrictor
1 bend + 3 meters 45 mm
1 bend + 4 meters 50 mm
1 bend + 5 meters No restrictor
FALCON
3.03 Top Outlet Concentric Flue Connection
3.03.1 Vertical concentric connection
Concentric
Vertical
Connector
A vertical connector can be supplied for vertical discharge
with concentric pipes.
The simple mounting and use of double lip gaskets at the
joints makes this an extremely easy and safe option.
Fig. 15
3.03.2 Horizontal concentric connection
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°.
Ø1
25-30 mm
Ø2
60
L
A=L+(85-90)mm
Detail of mounting the bend
Ø1
Ø2
Ø1=100 Ø2=60
Trim the 60 mm internal
diameter tube
Fig. 16
15
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