IDEAL Falcon GTS 4 Installation And Servicing Download Page 1 | Manualshive

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installation and
servicing

Your Ideal installation and servicing guide

When replacing any part on this appliance, use only spare parts that you can be
assured conform to the safety and performance specification that we require. Do not
use reconditioned or copy parts that have not been clearly authorised by Ideal Boilers.

Falcon GTS

GTS 4, GTS 5, GTS 6, GTS 7 & GTS 8

300013368-001-D

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Summary of Contents for Falcon GTS 4

Page 1: ...y part on this appliance use only spare parts that you can be assured conform to the safety and performance specification that we require Do not use reconditioned or copy parts that have not been clea...

Page 2: ...e important that no external control devices e g flue dampers economisers etc are directly connected to these appliances unless covered by these Installation and Servicing Instructions or as otherwise...

Page 3: ...et boilers offering high efficiency operation ease of maintenance fuel flexibility and low emissions in a compact package Suitable for oil or gas operation the Falcon GTS range is supplied in a choice...

Page 4: ...rature hot water heating systems of output greater than 45kW Part 1 Fundamental and design considerations Part 2 Selection of equipment Part 3 Installation commissioning and maintenance BS 6891 Instal...

Page 5: ...times 1mm of lime reduces the heat transfer from metal to water by 10 In practice the deposition of these salts is liable to cause noises from the boiler body or even premature boiler failure Corrosi...

Page 6: ...comply with local recommendations Refer also to Frame 3 1065 330 35 1 310 45 6 5 B E 1 2 1 4 A 56 51 56 520 FAL8519b 1 Adjustable feet basic height 50mm with 35 to 65mm adjustment range Boiler A B 4 E...

Page 7: ...the advice of the gas supplier should be obtained The temperature within a boiler room shall not exceed 25o C within 100 mm of the floor 32o C at mid height and 40o C within 100 mm of the ceiling Fil...

Page 8: ...ations or the requirements of the local authority as or water undertakings In general commercial closed pressurised systems are provided with either manual or automatic water make up In both instances...

Page 9: ...storage cylinder is less than that required by the boiler A combined shunt DHW primary pump sized on the minimum flow to be required MUST be fitted Provided adequate heat dissipation can be achieved a...

Page 10: ...whilst BS 5410 Pt 1 similarly applies to OIL fired boilers The table below contains the minimum dimensions of the flue required for each boiler model in order to ensure sufficient draught at the outl...

Page 11: ...nstructions delivered with the burner 12 ASSEMBLY Packaging The tables below show the numbers of the packages which make up the boiler The packages are listed in the order in which they are opened for...

Page 12: ...e groove facing up and fix the height converter with two M10 x 25 bolts serrated washers and nuts using a 17mm spanner 14 PREPARING THE SECTIONS 1 Support the rear section with a wooden block 2 Place...

Page 13: ...mall wooden block 4 Proceed likewise for the other intermediate sections FAL5823 3 3 17 ASSEMBLING THE FRONT SECTION AND PULLING UP COMPLETE ASSEMBLY 0mm 8227N022B 1 2 2 3 7 4 4 4 4 1 Complete the ass...

Page 14: ...signed for that purpose 1 Put the lower hinge in place press it against the front section and secure it with an M10 x 50 bolt and wide CL 10 20 tapered washer 17mm spanner 2 Screw in loosely the other...

Page 15: ...OPENING Assembling the door with left hand opening Proceed similarly with the hinges on the left hand side as described in Frames 19 and 20 22 POSITIONING THE FLUE BAFFLES 1 Open the door 2 Place the...

Page 16: ...the flue gas collector hood onto the studs and secure with two flanged nuts 1 FAL5832 FAL5833 2 24 FITTING THE FRONT CROSSPIECE 1 Lower the crosspiece onto the boiler body 2 Push it home behind the l...

Page 17: ...of the boiler with the black fabric facing downwards 2 Lift the insulating material around the body and fix it with two straps and bundles 3 Mount the lower and upper rear insulating material with the...

Page 18: ...EMBLING THE SIDE PANELS 1 Loosely fit the screws and serrated washers a to secure the control panel support and b to secure to the front cross piece Refer to Frame 26 2 Fit the cable clip on the oppos...

Page 19: ...and serrated washers into the front crosspiece 29 FITTING THE REAR PANEL 1 Remove the collector hood inspection plate by removing the wing nuts and washers 2 Place rear panel into position ensuring no...

Page 20: ...w for plastic fal8538b fal8537b 6 Fit the back of the control panel to the panel support using the self tapping screw and plain washer 7 Fit the earth wire spade connector to the earth tab 8 Insert th...

Page 21: ...h forwards to engage 2 Secure the top panel to the rear panel with 2 screws and serrated washers 3 Position the front panel so that the studs engage in the side panel keyhole slots Lower the panel to...

Page 22: ...essional The electrical wiring has been carefully checked in the factory and the internal connections of the control panel must not be modified in any event The electrical connections should be made f...

Page 23: ...36 DHW sensor optional The connector supplied in the AD 212 kit with the 22kOhm resistance and a 100nF capacitor must be plugged into terminals 25 and 26 Boiler sensor Heating pump not supplied Zone...

Page 24: ...om thermostat at terminals 19 and 20 zone B do not fit link if zone B not used Safety contact to terminals 4 and 5 after removing link Remote alarm to indicate overheat low water pressure etc to termi...

Page 25: ...NTROL RELAY CIRCUIT A HEATING PUMP CONTROL RELAY CIRCUIT B BOILER SENSOR DOMESTIC HOT WATER SENSOR TITANIUM ANODE ROOM THERMOSTAT CIRCUIT A ROOM THERMOSTAT CIRCUIT B SAFETY THERMOSTAT ALARM LIGHT MAIN...

Page 26: ...RL ECS TA M A T A ZEH 1 1a ZT ZT 1 1b 1a 2 2b 2a T EST ST B T EST ST B TS 1 2 3 B 1 2 DJ 6A fal8545 HEATING PUMP CIRCUIT A DHW LOAD PUMP HEATING PUMP CIRCUIT B BURNER A B B CS DJ6A J L N RL BR1 RL BR2...

Page 27: ...ion terminal for this control phase must be separate from those of the power supply phase s which are wired direct to the burner via the installer supplied burner mains relay No 8 N Neutral from contr...

Page 28: ...rrun 1 The potentiometer on the PCB in the boiler is used to adjust the DHW pump overrun The overrun can vary with an adjustment range from 0 to 10 minutes factory setting 4 min Setting the Domestic H...

Page 29: ...t the window 47 FUEL OIL OR GAS CONNECTIONS Refer to the instructions supplied with the burner 3 Unscrew the attachment screw fastening the front of the control panel 4 Tilt the front panel 5 Remove t...

Page 30: ...o C Notes for items 9 10 only Boilers fitted with a DHW sensor When the system is switched on it performs an air elimination sequence of the hot water calorifier lasting for 1 minute by intermittently...

Page 31: ...1 The correct operation of ANY secondary system controls should be proved Operate each control separately and check that the main burner or circulating pump as the case may be responds 2 Water circul...

Page 32: ...the seal Refer to Frame 29 10 Brush out the combustion chamber and vacuum the soot from beneath the flue ways 11 Replace the flue baffles into the flue ways Refer to Frame 22 for correct location 12 C...

Page 33: ...e system hot examine all water connections for soundness Check the gas rate and measure the combustion CO CO2 content Complete the boiler log book Carry out functional checks as appropriate 58 SERVICI...

Page 34: ...34 Falcon GTS Installation Servicing NOTES...

Page 35: ...35 Falcon GTS Installation Servicing NOTES...

Page 36: ...ance of its products The right is therefore reserved to vary specification without notice The Ideal Boilers Technical Training Centre offers a series of first class training courses for domestic comme...

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