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4

Falcon GTS - 

Installation & Servicing

GENERAL

SAFETY

Current Gas Safety (Installation and Use) Regulations or
rules in force.

It is law that all gas appliances are installed and serviced by a
Gas Safe Registered Installer in accordance with the
regulations below.  Failure to install appliances correctly could
lead to prosecution.  It is in your own interest, and that of safety,
to ensure the law is complied with.

The following must be conformed with:

Current Building Regulations and Clean Air Act

Water Authority Regulations

Local Authority Regulations and Regional Bylaws

Gas Safety Regulations

Any special regional requirements of local Electricity and Gas
undertaking.

Fire Service and Insurance Company requirements.

In the interests of safety, a competent installer should be
employed to effect the installation of the appliance.
Manufacturer's notes must NOT, in any way, be taken as over
riding statutory obligations.

The installation of the boiler MUST also be in accordance with
the latest I.E.E. (BS7671) Wiring Regulations, local buildings
regulations, bye-laws of the local water authority, the building
regulations and the Building Standards (Scotland) and any
relevant requirements of the local authority.

Detailed recommendations are contained in the following
Codes of Practice:

BS 799 Pt4 & 7

Oil burning equipment.

BS 799 Pt5

Oil storage tanks.

BS 5410 Pt1

Installation for space heating and hot water
supply.

BS 5440

Installation and maintenance of flues and
ventilation for gas appliances of rated input
not exceeding 70kW net (1st, 2nd and 3rd
family gases).

          Part 1

Specification  for  installation  of  flues

          Part 2

Specification  for  installation  and  maintenance
of ventilation for gas appliances.

BS 5854

Flues and flue structures in buildings.

BS 5885 Pt1

Gas burners - with inputs 60kW and above.

BS 6644

Installation of gas fired hot water boilers of
rated input between 70kW and 1.8MW (net)
(2nd and 3rd family gases).

BS 6798

Installation of gas fired hot water boilers of
rated input not exceeding 70kW.

NOTE TO THE INSTALLER: LEAVE THESE INSTRUCTIONS ADJACENT TO THE BOILER.

BS 6880

Low temperature 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

Installation of low pressure gas pipework of up
to 28mm (R1) in domestic premises (2nd
family gas).

EN 303.1

Heating boilers with forced draught burners.
General requirements.

EN 303.2

Heating boilers with forced draught burners
with atomising oil burners.

EN 304

Test code for heating boilers for atomizing oil
burners.

73/23 EEC

Low voltage directive. (Relevant standard is
EN60335.1)

89/336 EEC

Electromagnetic Compatibility Directive.
(Relevant standards are EN50081.1,
EN50082.1 and EN55014.)

90/396 EEC

Gas Appliances Directive. (Relevant standards
are EN303.1, EN303.2 and EN304.)

92/42 EEC

Boiler Efficiency Directive.

IGE/UP/1

Soundness testing and purging of industrial
and commercial gas installation.

IGE/UP/2

Gas installation pipework, boosters and
compressors on industrial and commercial
premises.

IGE/UP/10

Installation of gas appliances in industrial and
commercial premises.

SAFE HANDLING OF SUBSTANCES

Care should be taken when handling the boiler insulation
panels, which can cause irritation to the skin.  No asbestos,
mercury or CFCs are included in any part of the boiler or its
manufacture.

GAS SUPPLY

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 Gas Safe Registered Engineer.

An existing meter should be checked, preferably by the gas
supplier, to ensure that the meter is adequate to deal with the
rate of gas supply required.  A minimum working gas pressure
of 17.5mbar MUST be available at the boiler inlet.

Do not use pipes of smaller size than the burner inlet gas
connection.

The complete installation MUST be tested for gas soundness
and purged in accordance with the appropriate standards listed
above.

Assembly and Installation Instructions for Ideal Falcon GTS heating boilers should be read in conjunction with the general
technical data tables enclosed and any other technical publication supplied with the burner.

Содержание Falcon GTS 4

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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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