Ferroli Falcon II User guide

Appr. nr. B99.06 A - CE 0461 AU 04473543544/1 - 04/2005
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

FALCON II
2
CE MARK
CE mark documents that the FER 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
provided from them:
• Gas appliances directive 90/396
• Efficiencies directive 92/42
• Low tension directive 73/23 (modified from the 93/68)
• Electromagnetic compatibility directive 89/396 (modified from the 93/68)
Year 2000 Compliance Declaration
We will guarantee that this products is altogether suitable for the data change in the Year
2000 (boiler has no dependence from date change) and that no disruptions will occur which is
caused by this product.
IMPORTANT
Your "benchmark" Installation, Commissioning and Service Record Log Book is enclosed in the last pages of
this manual. “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 programme.
Benchmark has been introduced to improve the standards of installation and commissioning of
central heating systems in the UK and to encourage the regular servicing of all central heating
systems to ensure safety and efficiency.
Please see installation and servicing guidelines.
INDEX
1. DESCRIPTION........................................................................................................................................ 3
2. TECHNICAL AND DIMENSIONAL CHARACTERISTICS....................................................................... 4
3. INSTALLATION DETAILS ...................................................................................................................... 9
4. COMMISSIONING AND TESTING...................................................................................................... 21
5. ADJUSTMENT AND GAS CONVERSION ........................................................................................... 22
6. MAINTENANCE AND CLEANING ..................................................................................................... 24
7. REPLACEMENT OF PARTS ................................................................................................................. 26
8. FAULT FINDING.................................................................................................................................. 31
9. ELECTRICAL AND FUNCTIONAL SCHEME ....................................................................................... 38
10. USER INSTRUCTIONS ....................................................................................................................... 40
10. BENCHMARK .................................................................................................................................... 44

FALCON II
3
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

FALCON II
4
Fig. 1
2. TECHNICAL AND DIMENSIONAL CHARACTERISTICS
2.01 Technical information
Falcon II boilers are central heating and domestic hot water heat generators and are produced 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
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
23 5
1
189
460
Top view
120120
200
110
80
110
3 - 1/2 “ gas inlet
4 - 1/2" domestic hot water inlet
5 - 3/4" central heating return inlet

FALCON II
5
N.B. - The gas pressures at the burner and gas flows during the central heating phase given in the table refer
to nominal boiler output. To reduce this output (where necessary), gas pressure must be reduced until the
required output level is reached (see figures 4 and 5).
During domestic 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 input:
- Flow restrictor fitted (standard) - 1,2 bar;
- Flow restrictor removed - 0,5 bar
Technical Data

FALCON II
6
2.03 Boiler water flow diagram2.02 Boiler main components
Key
5 Room sealed compartment
7 Gas inlet
8 Domestic hot water outlet
9 Domestic hot water inlet
10 Central heating flow outlet
11 Central heating return inlet
14 Safety valve
16 Fan
19 Combustion chamber
20 Burner assembly
21 Main injector
22 Burner
26 Combustion 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
Fig. 2
Fig. 3
818222
29 43187
+
-
R
OVER RIDE
x
x
4
AUTO P
OI
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 8 784 85 44 136 14 42 9 11
36
98 63 157 145
0
5
1
234
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 vessel
62 Time clock
63 Central heating temperature adjustment
81 Ignition electrode
82 Sensor electrode
84 Primary gas valve solenoid
85 Secondary gas valve solenoid
90* Flue outlet test point
91* Air test point
98 On/Off/Reset switch
114 Low water pressure cut off switch
132 Flue gas deflector
136 Flow meter
145 Central heating pressure gauge
157 Domestic hot water temperature adjustment
187 Restrictor
*For use with flue gas analyser

FALCON II
7
2.05 Pump characteristics
The pump head available for circulating the water is
given in fig. 6.
N.B. - The pump is factory set at position 3. The pump
is a Grundfos type 15-50 UPS series.
Grundfos Pump performance graph
Note - Minimum flow through boiler heat exchanger at
any time should not fall below 6 litres per minute.
If the total volume of water in the system exceeds 40
litres an additional expansion vessel must be fitted to
the central heating return pipe.
Pump performance curve Grundfos UPS 15-50
Fig. 6
1 2 3 Speed settings
ABoilers pressure drop
BAvailable pump head C.H.
2.04 Central heating adjustment (not normally required)
To adjust boiler heat input (thus also regulating 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.
Adjusting boiler output to the actual requirements of the central heating system will minimise boiler
cycling thus saving fuel, varying the output has virtually no effect on the efficiency and combustion
characteristics of the boiler.
Diagram of pressures
and outputs with Natural gas
Fig. 4 Fig. 5
Diagram of pressures and outputs
with LPG (Propane)
2
3
4
5
6
7
8
9
10
11
12
13
12 13 14 15 16 17 18 19 20 21 22 23 24
11 12 13 14 15 16 17 18 19 20 21
kW
kcal/h
x 1000
mbar
14
25 26 27 28 29 30 31
22 23 24 25 26
kW
kcal/h
X 1000
m
b
ar
18 19 20 21 22 23
5
10
15
20
25
30
35
12 13 14 15 16 17
11 12 13 14 18 19 2015 16 17
25 26 27 28 29 3024
21 25 2622 23 24

FALCON II
8
SIZING OF ADDITIONAL EXPANSION VESSELS:
Deduct from the value given in the table the 10 litre
vessel supplied.
Note:
1. Fill C.H. installation to min. 1.5 bar.
2. Expansion vessel must be fitted to central heating
return pipe.
3. The standard 10 litre expansion vessel is charged
to 1 bar.
4. The additional expansion vessel should be charged
to 1 bar.
SAFETY VALVE
SETTING (bar)
VESSEL CHARGE
PRESSURE (bar)
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
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
Fig. 7
Pressure loss diagram
m |h
3
Q
8
7
6
5
4
3
2
1
00.5 1.5 2.512
Hmbar x 100

FALCON II
9
3.0 INSTALLATION DETAILS
Gas Safety (Installation & Use) Regulations: 1996
In the interest of safety, it is the law that all gas appliances are installed by a competent person in accordance
with the above Regulations, Building Regulations/Building Standards Scotland, Codes of Practice, current I.E.E.
Regulations and the byelaws of the Local Water Undertaking. Failure to comply with the Regulations may lead to
prosecution; it is your responsibility to ensure that the law is complied with.
N.B. For Northern Ireland the rules in force apply.
Important - If the boiler is to be fitted in a timber framed building it should be fitted in accordance with the Institute of
Gas Engineers document IGE/UP/7. If in doubt advice should be sought from the Local Supplier.
Location of Boiler
The installation of the Falcon II must be on a suitable non-combustible load bearing wall which will provide
an adequate fixing for the boiler mounting bracket assembly. The location should be in an area where
the water pipes will not be subjected to frost conditions. In siting the combination boiler the following
limitations must be observed:
The combination boiler may be installed in any room or internal space, although particular attention is drawn
to the requirements of the current I.E.E. wiring regulations and in Scotland the electrical provisions of the
building regulations applicable in Scotland, with respect to the installation of the combination boiler in a room
or internal space containing a bath or shower.
Where a room sealed appliance is installed in a room containing a bath or shower any electrical switch
or appliance control utilising mains electricity must be situated so that it cannot be touched by a person
using the bath or shower.
Air Supply
The room or compartment in which 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 flues, deduct 91mm plus distance from side
wall for side outlet flues). It is absolutely essential, to ensure that products of combustion discharging from the
terminal cannot re-enter the building, or enter any adjacent building, through ventilations, windows, doors,
natural air infiltration or forced ventilation/air conditioning.
Gas Supply
If necessary 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 Local Gas suppliers Contractor.
Installation pipes should be fitted in accordance with BS6891-1988.
Appliance inlet working pressure must be 20mbar MINIMUM, for NG and 37 mbar minimum for LPG.
Pipework from the meter to the combination boiler must be of an adequate size.
The boiler requires 3.5 m3/h of natural gas, and 2.60 kg/h of LPG.
Do not use pipes of a smaller size than the combination boiler inlet gas connection.
The complete installation must be tested for gas soundness and purged as described in BS6981-1988. All pipework
must be adequately supported. An isolating gas valve is provided and should be fitted on the boiler gas inlet.
Please wait 10 minutes when lighting from cold before checking gas rate. Gas pressures should be checked after
the boiler has operated for 10 minutes to reach thermal equilibrium.
Water System
Note - the boiler is designed for sealed systems only and must NOT be used on open vented systems.

FALCON II
10
Central Heating
Detailed recommendations are given in BS6798, BS5449, BS6700 and CP342 Part 2. Pipework not forming part
of the useful heating suface should be insulated to prevent any heat losses or possible freezing (i.e. in roof spaces
or ventilated underfloor spaces). Drain taps should be positioned at the lowest point of the system in accessible
locations to permit the whole system to be drained down. The drain taps should be in accordance with
BS2879. Copper tubing to BS2871, Part 1 is recommended for water carrying pipework. Pipework in
horizontal runs should have a gradient where possible to facilitate the removal of air. Ensure that the
boiler heat exchanger is not a natural point for air collection. A typical heating system with domestic
hot water circuit is illustrated in fig. 8.
Important - If thermostatic radiator vales are fitted a bypass must be fitted to ensure a minimum flow rate through
the boiler of 6 l/min. The bypass should be fitted as far as possible from the boiler.
Make Up Water
Provision must be made for replacing water lost from the sealed system. Reference should be made to BS6798,
for methods of filling and making up sealed systems. There must 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. 9.
Domestic Hot Water
Always fit a scale reducer in "hard water areas" (18 clarke degrees or over)". A 15mm copper connection point on
the boiler for attaching to the main supply is provided. The maximum domestic water pressure for the
inlet supply is 10 bar (145 P.S.I.). If the cold mains supply exceeds 5 bar (72 P.S.I.), a water governor
or pressure reducing valve must be fitted by the installer into the mains supply in an inconspicuous but
accessible position preferable between 3 and 5 metres (10-16ft) before the appliance. Such a valve must be
approved by the Water Research Council.
Attention - is drawn to the Model Water Byelaws.
Fittings manufactured from duplex (alpha-beta) brass
are not acceptable for underground use and certain
water undertakings will not accept their use above
ground.
Ensure all pipework is adequately supported
NOTE: A bypass must be fitted as far as possible
from the boiler if thermostatic radiator valves are
fitted thoughout.
Fig. 8
Gas
Cold water
Additional expansion
vessel C.H. (if required)
Filling
point C.H.
Bypass
Key
1. Filling point C.H.
2. Temporary connection
3. Cold water supply Fig. 9