Ferroli 47-26701 Installation, Servicing And User Instructions Manual Download Page 1 | Manualshive

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Appr. nr. B 9709A - CE n° 0063 AT 4967

INSTALLATION,

SERVICING AND

USER INSTRUCTIONS

G.C. NO: 47-26701

FALCON

C

OPPER

W

ALL

-M

OUNTED

C

OMBINATION

,

G

AS

F

IRED

B

OILER

FOR

C

ENTRAL

H

EATING

AND

D

OMESTIC

H

OT

W

ATER

P

RODUCTION

,

F

AN

A

SSISTED

, R

OOM

S

EALED

C

OMPARTMENT

,

E

LECTRONIC

F

LAME

I

GNITION

AND

C

ONTROL

3543272/0 - 09/00

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2
3
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Summary of Contents for 47-26701

Page 1: ...SERVICING AND USER INSTRUCTIONS G C NO 47 26701 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 3543272 0 09 00 ...

Page 2: ...hat no disruptions will occur which is caused by this product 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 ...

Page 3: ...SIONAL 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 ...

Page 4: ...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 tempe...

Page 5: ...uid Petrolium Gas converted appliances Key 1 3 4 central heating flow outlet 2 1 2 domestic hot water flow outlet R OVER RIDE x x AUTO P O I P bar C C 40 70 50 80 60 ON RESET OFF 0 bar 1 2 3 4 10 380 10 710 720 360 187 400 5 4 1 3 2 36 95 60 60 95 54 187 80 80 89 195 5 400 71 120 120 80 Top view Boiler connections 3 1 2 gas inlet 4 1 2 domestic hot water inlet 5 3 4 central heating return inlet Di...

Page 6: ... 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 injecto...

Page 7: ...80 50 70 40 C C 157 63 98 145 189 190 62 10 14 8 84 7 85 44 9 136 11 32 36 56 26 19 27 43 187 29 5 28 90 132 49 22 82 81 20 21 114 34 42 50 91 16 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 Expansion vessel 62 Time cl...

Page 8: ...PG 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 to 55 C by adj...

Page 9: ...1 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 The pu...

Page 10: ...oiler 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 flues...

Page 11: ...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 degrees or over A 15m...

Page 12: ...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...

Page 13: ...o 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 min ...

Page 14: ...RIC T O R RESTRICTOR FOR TWO PIPE SYSTEM Total flow resistance of flue system Use 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 With concentric systems Choose correct restrictor from table below With 2 pipe system Calculate the total flow resistance of the air and flue pipes in metres cap 3 08 2 utilise the table shown below to choose the more sui...

Page 15: ...l 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 conce...

Page 16: ...g 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: ...r 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 x metre of horizontal air induction pipe is indicated For every boiler model a maximum pipe length is provided expres...

Page 18: ... 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 female flue Ø100 Male female bend 45 Ø100 M...

Page 19: ...em 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 applica...

Page 20: ... 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 the...

Page 21: ... 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 designed so ...

Page 22: ...he 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 the pa...

Page 23: ...crew D clockwise toreduce pressure and anticlockwise to increase pressure 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 ...

Page 24: ... 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 differential must not be less than 1...

Page 25: ...iminary 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 boiler for hot water check inlet p...

Page 26: ...ter 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 for air 3 Open the air and flue gas test points 4 Introduce the probes as far as the retainer ...

Page 27: ...in either or both the central heating or domestic hot water circuits of the boiler only The cold water mains inlet is isolated at the inlet cock The D H W is drained by opening a hot tap The C H flow and return cocks are turned off at the isolation cocks The C H is drained via the pressure relief valve twist about 1 2 of a turn c Remove components following special notice below and replace in reve...

Page 28: ...0 A B C D 7 07 D H W temperature sensor or Central Heating Temperature Sensor fig 31 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 31 Disconnect electrical connection to the sensor Drain the boiler Unscrew the sensor Replace in reverse order 7 11 Water Pressure Switch fi...

Page 29: ...d 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 thermostat f...

Page 30: ...e 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 unions A ...

Page 31: ... 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 ensure ...

Page 32: ... 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 calling for...

Page 33: ...ated 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 controls ...

Page 34: ...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 230 V...

Page 35: ...ar 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 Gas ...

Page 36: ...ain board Check and if necessary replace limit thermostat Go to chart 4 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 is necessary re...

Page 37: ...itch 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 m...

Page 38: ... 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 and i...

Page 39: ...P04 X3 X5 X4 1 2 X6 H1 Reset H2 Flame X1 1 2 3 4 5 6 7 8 9 1 0 1 1 1 2 3 4 X2 P4 P5 1 2 X7 S4562DM1006 IGNITION CONTROL Potentiometer adjustment Location P1 Central heating flow temperature adjustment P C B main board P2 Domestic hot water temperature adjustment P C B main board P3 Central heating flow output adjustment P C B main board P4 Ignition gas pressure adjustment Ignition control P5 Facto...

Page 40: ... P2 X6 X7 P3 OUT 136 50 114 42 34 10 1 49 X1 1 2 3 4 5 6 7 8 9 1 0 1 1 1 2 3 4 X2 43 16 98 C NO L N X1 X2 L N 32 72 80 230V 2 2 1 N L 2 3 4 9 8 7 6 5 4 3 2 1 1 3 P4 P5 1 2 44 MV1 MV2 MV3 MV4 24 V X7 S4562DM1006 NAT LPG 230 V 24 V 230 V RY01 RY02 JP04 R R Blue Blue O O Blue BR BL BL G R W Blue BR Blue BR Blue BR Blue BR Blue BR Blue W BL BR W O Blue V BL R 4 3 IMPORTANT USE A ROOM THERMOSTAT 24 V W...

Page 41: ...N 24V AC RY02 X1 1 L N X1 2 98 JP01 JP02 JP04 X1 9 X1 10 X1 11 Main Board MV2 MV3 MV4 114 X7 5 X7 6 50 X7 3 X7 4 136 bar 0 6V NAT LPG 9 03 Functional flow diagram MF02 S4562DM1006 Key 16 Fan 32 Central heating pump 34 Central heating flow temperature sensor 42 Domestic hot water flow temperature sensor 43 Air pressure switch 44 Gas valve 49 Safety thermostat 50 Central heating limit thermostat 62 ...

Page 42: ...ted power on Turn the temperature regulator 2 to the position Open a hot water tap green light tap symbol comes on fan starts and burner will light Indicated by flame symbol green light coming on The temperature of the hot water can be 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 hea...

Page 43: ...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 of thi...

Page 44: ...ntral 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 Reset with pencil only with switch A in set clock...

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Page 48: ...ervice 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 ...

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