Fer FALCON II Installation, Servicing & User Instructions Download Page 3

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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. 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

• 16 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.

• Flowmeter 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

Summary of Contents for FALCON II

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

Page 2: ...closed 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 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...

Page 3: ...l 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 tem...

Page 4: ... 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 733 460 430 85 14 362 200 720 Ø60 115 Ø100 75 189 Distance between connections 36 95 60 60 155 54 175 Bottom view 4 2 3 5 1 189 460 Top view 120 120 200 110 80 110 3 1 2 gas inlet 4 1 2 domestic hot water inlet 5 3 4 central heating return inlet ...

Page 5: ...ic 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 flow 85 C Maximum temperature of domestic hot water 55 C adjustable between 40 C and 55 C Minimuum domestic cold water pressure required for 95 heat in...

Page 6: ...O P O I P IN OUT MIN GRUNDFOS FERROLI 114 34 20 21 90 50 16 28 32 26 19 49 132 5 56 27 91 62 10 8 7 84 85 44 136 14 42 9 11 36 98 63 157 145 0 5 1 2 3 4 6 OUT I MIN AIR IN AIR IN FLUE OUT C H OUT D H W OUT GAS IN D H W IN C H IN 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 Expansion vesse...

Page 7: ...ting 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 Adjustingboileroutputtotheactualrequirementsofthecentralheatingsystemwillminimiseboilercyclingthussavingfuel varying the output has virtually no ef...

Page 8: ...INITIAL SYSTEM PRESSURE bar TOTAL WATER CONTENT of SYSTEM 3 0 0 5 1 0 1 5 1 0 1 5 2 0 1 5 2 0 2 0 EXPANSION VESSEL VOLUME litres LITRES 25 3 5 6 5 13 7 4 7 10 3 8 3 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 8 100 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 ...

Page 9: ...he 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 f...

Page 10: ...nection 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 9 Domestic Hot Water Always fit a scale reducer in hard water areas 18 clarke degrees or over A 15mm co...

Page 11: ... 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 ...

Page 12: ...all 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 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 12b ...

Page 13: ...ectly positioned see fig 13 N B the diameter of the hole is stamped on the restrictor Boiler is fitted with Ø47 restrictor as standard Holes Ø 47 50 52 Ø Fig 13 Choice of restrictor With concentric pipes up to 1m long one bend use the 52 mm restrictor for flue lengths over 1 metre use no restrictor With 2 pipe system Calculate the total flow resistance of the air and flue pipes in metres cap 3 04 ...

Page 14: ...Vertical concentric connection 1KWMA31Y D S L 125 70 50 30 95 80 80 3 mm m Ø60 Ø80 70 min between 10 e 60 mm 190 270 Fig 15 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 14 Concentric Vertical Connector 3 03 2 Horizontal concentric connection L S D 25...

Page 15: ...e gas duct must be sealed with the gasket where they join the boiler fig 16 Outside the pipes should protrude from the wall between 10 and 60 mm fig 16 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...

Page 16: ...with non combustible insulating material to prevent condensation The flue pipe should be supported at intervals of not more than 1 8m and the support should be preferably below a joint 3 04 2 Two pipe flue system To determine the maximum length of flue and air pipe permissible The calculation is based on a standard reference resistance of 1 metre of 80 mm horizontal air intake pipe For every confi...

Page 17: ...minal Ø 80 mm Outlet flue air inlet for concentric system Ø 100 60 mm Pipe fitting for outlet flue Ø 80 mm Outlet flue air inlet for connection with split end Ø 80 mm 1 1 1 2 1 2 2 2 1 5 2 5 REDUCTION 5 2 4 AIR FLUE Vertical Horizontal Vertical Horizontal REDUCTION 12 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 Ø 100 80 mm 0 3 04 2 continued Tab 1 Pipes and ...

Page 18: ... 7 6 3 2 5 1 13 m 13 m Fig 19 Example of wall inlet outlet 2 pipe application Example of roof inlet outlet Example of direct roof flue outlet and wall air inlet 3 04 3 Example of other installation with two pipe systems Fig 20a Fig 20b Fig 20c REF N OF PIECES DESCRIPTION LENGTH OR 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 5 1 Flue bend ...

Page 19: ...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 in...

Page 20: ...afety device which allows 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 ...

Page 21: ...p procedure correctly the burners fail to ignite 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 minute delay before starting up again If after a second ...

Page 22: ...the right pressure adjust minimum pressure by potentiometer P5 Adjust potentiometre P3 at maximum clockwise 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 see paragraph 5...

Page 23: ...t requirements 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 min...

Page 24: ...d pull forward 4 Carry out preliminary electrical checks at boiler junction box 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 boi...

Page 25: ...st is carried out normally 10 15 minutes CO CO2 ratio should not exceed 0 0080 Immediately after servicing 0 0040 at any other time 30 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 f...

Page 26: ...re Re 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 24 Remove the two fixing screw ...

Page 27: ... Water pressure switch D H W sensor Safety valve A B C D D C A F E 7 07 D H W temperature sensor or Central Heating Temperature Sensor fig 28 Isolate electricity and water supplies Remove outer case two screws bottom rear corners Remove the two securing screws and lower control panel Identify the sensor from figure 28 Disconnect electrical connection to the sensor Drain the affected service either...

Page 28: ...ctricity 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 13 Limit thermostat or overheat cut off thermostat fig 30...

Page 29: ...emove 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 other absorbent 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 30: ...mp 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 taking care to ensur...

Page 31: ...he 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 calling for heat If both internal a...

Page 32: ...t the flow meter has not 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 eli...

Page 33: ...ntrol 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 ...

Page 34: ...ck 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 5ϒ 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 Gas suppl...

Page 35: ...ecessary replace limit thermostat Go to chart 4 NO Check and if necessary replace pump Chart 3 Check Central Heating operation 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 ...

Page 36: ...witch 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 Chart 5 Check D H W and C H modulation Does burner flame modulate Normal operation carry out YES NO Boiler operated on central heating ...

Page 37: ...eck 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 an...

Page 38: ...ture adjustment P3 Central heating flow output adjustment P4 Ignition gas pressure adjustment P5 Minimum adjustment pressure 9 ELECTRICAL AND FUNCTIONAL SCHEME 9 01 Main components layout on electronic boards 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 34 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 L4 L...

Page 39: ...CTS CONNECTING 230 V TO THE ROOM THERMOSTAT TERMINALS WILL IRREPARABLY DAMAGE THE ELECTRONIC BOARD 81 Ignition electrode 82 Sensor electrode 98 Off On Reset switch 114 Low water pressure switch 136 Flow meter 9 02 General wiring diagram 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 JP03 Na...

Page 40: ...crease the water temperature Heating and Hot Water WINTER To obtain heating from the boiler turn the temperature regulator B 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 as indicated by the red light egg timer symbol on the left of the facia panel When this light go...

Page 41: ... 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 of this appliance may not correspond with the coloured markings identifying the terminal in the plug Therefore proceed as follows The wire coloured green and yellow mus...

Page 42: ...1 Use button and to set 2nd ON time eg 12 30 Display 4 1 Use button and to set 2nd OFF time eg 14 00 Display 5 1 Use button and to set 3rd ON time eg 16 00 Display 6 1 Use button and to set 3rd OFF time eg 23 30 Display 8 On completion of programming slide switch A to Auto position the time of day will be displayed and the central heating will switch ON and OFF according to the programme set 1 Sli...

Page 43: ......

Page 44: ...ties call our Technical Service Helpline on 08707 282 885 PO BOX 3774 Sutton Coldfield West Midlands B76 8DH Tel 08707 282 885 Fax 08707 282 886 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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