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

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INDUSTRIE

FALCON

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. A special feature of this boiler is its built-in electronic flame ignition and control unit making burner operation
completely automatic and safe. The main components are as follows:
• Copper heat exchanger consisting of three finned tubes specifically shaped for high efficiency.
• 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 fibre insulated combustion chamber
• 12 stainless steel bladed burners specifically 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 flow temperature adjustment thermostat.
• Domestic hot water flow temperature adjustment thermostat.
• Central heating limit thermostat.
• Overheat safety thermostat.
• Electronic control unit for automatic flame ignition and control.
• Central heating low water pressure cut off switch.
• Domestic hot water flow temperature sensor.
• Central heating flow temperature sensor.

1.02 Instructions and regulations

Assembly, installation, first 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

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Summary of Contents for Falcon 47-26701

Page 1: ...G AND USER INSTRUCTIONS G C NO 47 26701 INDUSTRIE FALCON 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 3543909 1 ediz 02 2002 ...

Page 2: ... UK and to encourage the regular servicing of all central heating systems to ensure safety and efficiency 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 specifications prov...

Page 3: ...imensional 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 41 ...

Page 4: ...tral heating circuit set to open at 3 bar Built in Expansion vessel Variable speed pump Central heating flow temperature adjustment thermostat Domestic hot water flow temperature adjustment thermostat Central heating limit thermostat Overheat safety thermostat Electronic control unit for automatic flame ignition and control Central heating low water pressure cut off switch Domestic hot water flow ...

Page 5: ...as standard to function with natural gas or Liquid Petrolium Gas converted appliances Key 1 3 4 central heating flow outlet 2 1 2 domestic hot water flow outlet 3 1 2 gas inlet 4 1 2 domestic hot water inlet 5 3 4 central heating return inlet 10 380 10 710 720 360 400 36 95 60 60 95 54 187 80 80 89 195 5 400 71 120 120 80 5 4 3 2 1 Top view Boiler connections Distance between connection ...

Page 6: ...input Domestic hot water heat input Boiler water contents Domestic hot water circuit contents kW kW kW kW kW Litres Litres FALCON 23 3 9 7 25 8 11 5 23 3 1 5 0 8 MODEL Connections Expansion vessel Max working pressure central heating circuit Max working pressure hot water circuit 1 2 3 4 5 Capacity Pre pressurising value Ø Ø Ø Ø Ø Litres bar bar bar FALCON 3 4 1 2 1 2 1 2 3 4 7 1 3 6 MODEL Main in...

Page 7: ...chamber insulation 27 Copper heat exchanger for central heating and domestic hot water 28 Flue collector from heat exchanger 29 Internal flue exit 32 Central heating pump 34 Central heating flow temperature sensor 36 Automatic air vent valve 42 Domestic hot water flow temperature sensor 43 Air pressure switch 44 Gas valve 49 Safety overheat thermostat 50 Central heating flow limit thermostat 56 Ex...

Page 8: ...outputs with LPG Propane 2 3 4 5 6 7 8 9 10 11 12 13 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 kW kcal h x 1000 mbar 14 kW kcal h X 1000 mbar 18 19 20 21 22 23 10 15 20 25 30 35 9 10 11 12 13 14 15 16 17 9 10 11 12 13 14 18 19 20 15 16 17 8 2 05 Domestic hot water variability characteristics The temperature of the domestic hot water can be varied from 40 ...

Page 9: ...9 4 41 3 14 2 30 9 24 8 100 14 0 25 9 55 1 19 0 41 2 33 1 125 17 5 32 4 68 9 23 7 51 5 41 3 150 21 0 38 8 82 6 28 5 61 8 49 6 175 24 5 45 3 96 4 33 2 72 1 57 9 200 28 0 51 8 110 2 38 0 82 4 66 2 0 140 0 259 0 551 0 190 0 412 0 33 For syst volumes other than those given above mult the syst volume by the factor across m h 3 Q 8 7 6 5 4 3 2 1 0 0 5 1 5 2 5 1 2 H mbar x 100 2 06 Pump characteristics T...

Page 10: ...the boiler is installed does not require a purpose provided vent when using the standard concentric flue Flue System The boiler allows the flue outlet to be taken from the rear of the boiler from either side or vertically A standard flue 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 ...

Page 11: ...t 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 filling loop is shown in fig 10 Domestic Hot Water Always fit a scale reducer in hard water areas 18 clarke degree...

Page 12: ...evel 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 t...

Page 13: ...ket 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 fix 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 flue 1 CH flow 2 Safety Valve 3 Domestic hot water outlet 4 Gas supply 5 Domestic hot water inlet 6 CH return Fig 13b 15 min 5...

Page 14: ...r e s U r o t c i r t s e r e s U r o t c i r t s e r e s U e z i s e z i s e z i s e z i s e z i s m u m i n i m m u m i x a m m m m 0 m 3 1 5 4 m 3 1 m 3 2 7 4 m 3 2 m 8 3 0 5 m 8 3 m 8 4 r o t c i r t s e r o N M E T S Y S C I R T N E C N O C R O F R O T C I R T S E R M E T S Y S C I R T N E C N O C R O F R O T C I R T S E R M E T S Y S C I R T N E C N O C R O F R O T C I R T S E R M E T S Y S ...

Page 15: ...rtical concentric connection L A L 85 90 mm Ø2 Ø1 25 30 mm 60 Ø2 Ø1 Ø1 100 Ø2 60 Fig 16 Trim the 60 mm internal diameter tube Detail of mounting the bend 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 Concentric Vertical Connector 3 03 2 Horizontal ...

Page 16: ...ig 17 Between 10 60mm 3 03 3 Maximum concentric flue length First table below shows the maximum flue lengths available for boilers with concentric systems For correct calculation remember to include the reduction for bends on second table Please refer to 3 02 for use of restrictor Maximum flue lenght permissible 100 mm concentric 125 mm concentric Vertical Horizontal Vertical Horizontal Falcon 4 m...

Page 17: ...ter 80 for the maximum length permissible for all the pipes fittings flow resistance coefficient In other words for all components and pipes in the different installation configurations vertical or horizontal air or flue etc and for all the fittings a flow resistance reduction equivalent to xmetre of horizontal air induction pipe is indicated For every boiler model a maximum pipe length is provide...

Page 18: ...itting for outlet flue Ø80 Outlet flue air inlet for connection with split end Ø80 1 1 1 2 1 2 2 2 1 5 2 5 1 5 2 5 7 Reduction 2 4 3 Air Flue Vertical Horizontal Vertical Horizontal 12 Condensate flue outlet A c c e s s o r i e s Ø 8 0 A c c e s s o r i e s Ø 8 0 Spigot and socket reduction Ø80 100 0 Reduction Airwall terminal products of combustion Ø80 5 Male fem ale flue Ø100 Male female bend 45...

Page 19: ... system maximum total flue length 48 metres 7 4 6 3 2 5 1 12 m 12 m Fig 20 REF N DESCRIPTION LENGTH OR OF PIECES REDUCTION 1 1 Air bend 80 mm R D 0 75 1 5 m 2 13 Horizontal air pipe 13 0 m 3 1 Air wall terminal 2 0 m 4 1 Air inlet closing flange 5 1 Flue bend 80 mm R D 0 75 2 5 m 6 12 Horizontal flue 24 0 m 7 1 Air wall terminal outlet flue 5 0 m TOTAL 48 0 m Example of wall inlet outlet 2 pipe ap...

Page 20: ... when hot should be about 1 5 2 bars After filling always close and disconnect the filling loop Note If there is a possibility of air pockets forming in certain points of the central heating system flow and return pipes you are recommended to fit an air vent valve at these points Note When the boiler is installed below the level of the central heating a system single check valve should be fitted i...

Page 21: ...s the main burner to ignite only after having verified that the fan is working correctly If the difference in pressure between the flue gas discharge pipe and the air intake pipe is not at least equal to the minimum pressure switch calibration value the pressure switch contacts do not close and the gas valve is thus prevented from opening In addition the electrical circuit of the boiler is designe...

Page 22: ...and the boiler shut down warning lights up wait about 15 seconds then rotate the knob 98 fig 2 against spring pressure to the RESET position and release it The reset electronic control unit will repeat the start up cycle Note In central heating mode after resetting the boiler will go into it 2 minue delay before starting up again If after a second attempt the burners still fail to ignite consult t...

Page 23: ...screw D clockwise toreduce pressure and anticlockwise to increase pressure Adjust potentiometre P3 at maximum anticlockwise Adjust max pressure by rotating screw E clockwise to increase pressure and anticlockwise to reduce pressure Reconnect the pressure compensation tube F Replace protective cap C Maximum Minimum possible gas pressures are now set Range Rating the central heating is not necessary...

Page 24: ...rements 5 07 Adjusting the central heating flow t by varying pump flow head The thermal head t the difference in temperature between the delivery water and return water in the central heating circuit must be less than 20 c This is obtained by varying pump flow rate and head using the multi speed variator or switch on the pump itself Increasing the pump speed reduces t and vice versa The minimum di...

Page 25: ... This is located in the centre of the boiler at the bottom and can be accessed be the removal of a single screw Any faults found must be rectified before proceeding 5 If electrical checks prove O K replace cover and secure with screw 6 Attach a manometer to the boiler gas inlet test point turn on electricty and fire boiler for hot water check inlet pressure This should be 20mbar minimum for NG and...

Page 26: ...Refit case and secure with screws 31 Leave boiler set to customers requirements 6 04 Flue Gas Analysis 1 The appliance should be checked visually for obvious defects 2 After removing the jacket on the boiler there are two test point one for flue gas and the other for air 3 Open the air and flue gas test points 4 Introduce the probes as far as the retainer 5 Turn on the hot water tap 6 Turn the dom...

Page 27: ...open cocks and re charge the system to about 1 bar and vent boiler and radiators Re charge to 1 bar if necessary Upon completion of the work the following Should be checked I Gas soundness of all joints II Water soundness of all joints III The electricity supply IV The pressure of the sealed system and top up where necessary 7 03 To lower the control panel fig 27 Remove the two fixing screw fig 27...

Page 28: ...he boiler Release the outlet union to the valve and undo the valve union connection Remove the valve outlet fitting Replace in reverse order 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 Disconnect plastic tube C Loosen the connection...

Page 29: ...e gas and electricity supplies Remove outer case two screws bottom rear corners Remove room sealed cover Disconnect fan electrical leads A and note positions Disconnect air pressure tubes from air pressure switch B note positions Undo two screws securing fan assembly C Remove fan from boiler Swap mounting plate over to new fan replace in reverse order 7 11 Limit thermostat or overheat cut off ther...

Page 30: ...Remove outer case two screws bottom rear corners Remove two screws from control panel and tilt forward Take off protective cover from main PCB and unplug flow meter lead from terminal X6 Place a piece of cloth or some otherabsorbent material over rear of control panel to catch any drops of water that may be released when removing the flow meter Using a 24mm open ended spanner undo flow meter union...

Page 31: ... the rear of the pump body by removing the U clip from the left hand side Disconnect the boiler return pipe and disengage the pump lower connection by removing the U clip C Disconnect the pump to heat exchanger connection by removing the U clip F Unscrew the two screws on bottom of pump D Turn the pump body through 90 pull the bottom forward and withdraw the pump body Reassemble in reverse order t...

Page 32: ...s i e stand by mode Note If the boiler thermostat is set to maximum than the burner pressure will go to maximum effectively bypassing the auto range rating facility Domestic Hot Water Mode External Call for D H W Flow meter registers at least 2 5 litres min flow to the hot water taps Internal Call for D H W Hot water flow temperature sensor 88 C high limit stat and low water pressure switch callin...

Page 33: ... operated Boiler will not light for C H If the boiler works for D H W but not for heating the fault is most likely to be external controls i e clocks or room thermostats Integral clock if fitted or C H sensor If the heating demand light is on the fault is most likely the C H sensor If this light is not on suspect either a clock or room thermostat not calling To override eliminate any external cont...

Page 34: ...ol C H output and maximum D H W temperature both are adjustable by the controls on the facia and because the boiler features automatic range rating no adjustments need to be made Electro mechanical relays control pump operation and put switched live to the ignition PCB demand relay they have transparent plastic covers so that their contacts can be seen moving 8 08 Air pressure switch Operating at ...

Page 35: ...1 5 bar Check water pressure switch wiring connection NO Does fan run at full speed NO Go to CHART 2 NO YES Does CH Pump run If the boiler temperature is less than 5 C frost protection is activated Disconnect CH flowtemp sensor Has fan speed stopped Check and if necessary replace main board NO YES YES Check and if necessary replace water pressure switch Chek the following carefully before starting...

Page 36: ... YES YES YES Check and if necessary replace main board Check and if necessary replace limit thermostat Go to chart 4 Wait 2 minutes DHW taps closed Put CH temperature selector to maximum Ensure external controls are calling for heat Is LED4 flashing Does C H pump run YES YES Go to chart 4 Is relay RY101 switch on Check and if necessary replace main board NO Is LED4 flashing Check and if is necessa...

Page 37: ...eck and if necessary replace air pressure switch YES Differential air pressure across the air pressure switch is greater than 180 Pascal Go to chart 5 YES NO Check and clean fan Check flue and air intake are correct and clean Check Venturi and air pressure switch tubes are clean Check restrictor is correct Does burner flame modulate Normal operation carry out YES NO Boiler operated on central heat...

Page 38: ...Check electrodes and leads for damage and correct connection Check and if necessary replace P C B Adjust with P4 ignition burner pressure Check and if necessary clean burner Check and if necessary clean injectors Check and if necessary clean flame electrode Check right position of spark electrode Check wires Check gas supply is live and purged Check and if necessary replace gas valve NO YES Check ...

Page 39: ...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 temp Ohm 10 C 20 kOhm 25 C 10 kOhm 60 C 2 5 kOhm 80 C 1 25 kOhm Temp sensor NTC 34 42 Fig 40 X6 X1 X2 X3 X4 1 2 1 2 1 3 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 2 1 X5 L1 L2 L3 L...

Page 40: ...AGE TO THE CONTACTS CONNECTING 230 V TO THE ROOM THERMOSTAT TERMINALS WILL IRREPARABLY DAMAGE THE ELECTRONIC BOARD 72 Room thermostat 81 Ignition electrode 82 Sensor electrode 98 Off On Reset switch 114 Low water pressure switch 136 Flow meter X6 X1 X2 X3 X4 1 2 1 2 1 3 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 2 1 X5 TEST X12 1 2 1 2 3 4 5 6 7 8 9 X10 W O V R X8 X7 81 82 MF03F JP02 JP01 ...

Page 41: ...e adjusted by turning the hot water thermostat 1 clockwise to increase and anti clockwise to decrease the water temperature Heating and Hot Water WINTER To obtain heating from the boiler turn the temperature regulator 2 clockwise to the maximum position ensure that any other heating controls e g room thermostats clock etc are in the on position The boiler may be in heating delay of three minutes a...

Page 42: ... gas appliances are installed and serviced by a competent person in accordance with the Gas Safety Regulations Installation Use 1996 and the manufacturers instructions Failure to observe these requirements may lead to prosecution Electrical Supply WARNING This appliance must be earthed The electrical wiring must be carried out by a competent electrician The colours of the wires in the mains lead o...

Page 43: ...tch A can be moved to the Auto position and the central heating will be ON for these periods 12 00 12 00 will not switch on the boiler A Slide switch set clock auto set programme B Display Symbol in Display Timer ON P Select programme ON OFF 1 8 D Push buttons Time Time E Override Boiler will switch ON if boiler is OFF and OFF if is ON F I Heating continuous AUTO Heating timed O Heating disabled R...

Page 44: ...e Engineer BECAUSE OF OUR CONSTANT ENDEAVOUR FOR IMPROVEMENT DETAILS MAY VARY SLIGHTLY FROM THOSE QUOTED IN THESE INSTRUCTIONS 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 INDUSTRIE ...

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