Ferroli Falcon User guide

Appr. nr. B 9709A - CE n° 0063 AT 4967
INSTALLATION,
SERVICING AND
USERINSTRUCTIONS
G.C. NO: 47-26701
F LCON
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

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CE MARK
CE mark documents that the Ferroli 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,CommissioningandService RecordLogBookwill beenclosedin
yourcustomer information pack.
"Thisrecordmustbecompletedandleftwiththeenduser"
"All CORGI RegisteredInstallerscarryaCORGI IDcardandhavearegistration number.Bothshould
berecordedin yourcentral heatinglogbook. Youcan checkto theCORGI registeredby calling
CORGI on 01256 372300".
Ferroli 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.

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NDEX
1. DESCRIPTION ..................................................................................................................................... 4
. TECHNICAL AND DIMENSIONAL CHARACTERISTICS.......................................................................
. INSTALLATIONDETAILS................................................................................................................... 1
. COMMISSIONINGAND TESTING....................................................................................................
. ADJUSTMENT AND GAS CONVERSION ..........................................................................................
. MAINTENANCE AND CLEANING....................................................................................................
. REPLACEMENTOFPARTS.................................................................................................................
. AULT INDING...............................................................................................................................
. ELECTRICAL AND FUNCTIONAL SCHEME.......................................................................................
1. USER INSTRUCTIONS....................................................................................................................... 4

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1. DESCRIPTION
1.01 Introduction
The Falcon is definedas a“room sealed” combination boiler, all air requiredfor combustion is takenfrom outside the
room in which it is installed. It is anewhigh performance gas firedheat generator for central heating and domestic hot
waterproduction. Aspecial feature of this boileris its built-in electronic flame ignition and control unit making burner
operation completely automatic and safe.The main components are as follows:
•Copperheat exchangerconsisting of three finnedtubesspecifically shapedfor high efficiency.
•There are three coppercoils insertedin the three heating circuit tubes. These represent the domestic hot waterheat
exchanger. Their shape and high exchange surface areaenable the full output of the boilerto be absorbed.
•Ceramic fibre insulatedcombustion chamber
•12 stainless steelbladedburners specifically designedfor this boiler.
•Fan for discharge of combustion products and intake of combustion air.
•Differential air pressure switch.For safety reasons, this ensuresthe burnerignitesonly whenthe fan is functioning correctly.
•Hermetically sealedcompartment made from corrosion-resistant steelenclosing the above components.
•Combination gas safety valve with modulator, complete with pressure stabiliser.
•Flow metergiving the domestic hot watercircuit precedence overthe central heating circuit.
•Pressure reliefvalve for the central heating circuit setto openat 3bar.
•Built-in Expansion vessel.
•Variable speedpump.
•Central heating flow temperature adjustment thermostat.
•Domestic hot waterflow temperature adjustment thermostat.
•Central heating limit thermostat.
•Overheat safety thermostat.
•Electronic control unit for automatic flame ignition and control.
•Central heating low waterpressure cut off switch.
•Domestic hot waterflow temperature sensor.
•Central heating flow temperature sensor.
1.02Instructionsand regulations
Assembly, installation, first start up and maintenance must be carriedout by competent persons only, in accordance
with all current technical regulations and directives.
.O.S.H.H.
Materials usedin the manufacture of this appliance are non hazardous and no special precautions are required
whenservicing.
Related Documents
Thisappliancemust beinstalled strictlyin accordancewiththese instructions.
The Gas Safety Regulations (Installations &Use)1996.
The Local Building Regulations.
The Building Regulations.
The Buildings Standards (Scotland -Consolidated)Regulations.
British Standards Codesof Practice:
B.S.75931992TREATMENT OF WATERINDOMESTIC HOT WATERCENTRALHEATING SYSTEMS
B.S.5546 1990 INSTALLATIONOF HOT WATERSUPPLIESFORDOMESTIC PURPOSES
B.S.5440 PART 1FLUES
B.S.5440 PART 2AIRSUPPLY
B.S.5449 1990 FORCED CIRCULATIONHOT WATERSYSTEMS
B.S.6798 1987 INSTALLATIONOF GASFIRED HOT WATERBOILERS
B.S.68911989 GASINSTALLATIONS
B.S.76711992IEE WIRING REGULATIONS
B.S.48141990 SPECIFICATIONFOREXPANSIONVESSELS
B.S.54821994 INSTALLATIONOF LPG
ModelWaterBye Laws
For Northern Ireland the rulesin force apply

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Fig. 1
2. TECHNICAL AND DIMENSION L CHRCTERISTICS
2.01 Technical information
Falcon 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"domestichot water flow outlet
+
-
R
OVERRIDE
x
x
AUTO P
OI
P
bar CC
40
70
50
80
60 ON
RESET
OFF
0bar
123
4
10 380 10
710
720
360
187
400
5
4
13
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“gasinlet
4-1/2"domestichot water inlet
5-3/4" central heating return inlet
Distance between connection

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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 untilthe required
output levelis reached (see figures 4and 5).
During domestic hotwater production,gas pressures to the burner must correspondtothe maximum output
given in table forthe type ofgas.
Gas pressure must beadjustedduring maximum draw-off ofdomestic hotwater.
•Maximum working temperature forcentral heating flow:85°C
•Maximum temperature ofdomestic hotwater:55°C, adjustable between 40°C and55°C.
•Minimum domestic coldwater pressure requiredfor95% heat input:
- Flowrestrictorfitted(standard)- 1,2 bar;
- Flowrestrictorremoved- 0,5 bar
TechnicalData
MODEL Heat output Heat
input
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
12345Capacity Pre-pressurising
value
ØØØØØLitres bar bar bar
FALCON 3/4” 1/2” 1/2” 1/2” 3/4” 7 1 3 6
MODEL
Main injectors (mm) Gas flow rates to main burners
for central heating Gas valve
Ø 1/2”
G20 - NG G31 - LPG G20 - NG G31 - LPG
ØØ m
3/h kg/h
FALCON 12x1,30 12x0,77 2,73 2,00 H. V K4105G
MODEL
Gas supply pressures Gas pressure at main burner for central heating
Safety valve
G20 - NG G31 - LPG G20 - NG G31 - LPG
minimum nominal minimum nominal
mbar mbar mbar mbar mbar mbar bar
FALCON 20 37 2,5 11,8 7,8 36,0 3
MODEL
Domestic hot water
production with
∆t 30°C
Domestic hot water
production with
∆t 35°C
Max. working pressure
domestic hot water Protection
level
Weight
G20 - NG G31 - LPG
l/min. l/min. mbar mbar kg
FALCON 11,1 9,5 11,8 36,0 IP44 38

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2.03 Boiler water flow diagram
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
Fig. 3
2.02 Boiler maincomponents
Fig. 2
Key
5 Room sealed compartment
7Gas inlet
8Domestichot water outlet
9Domestichot water inlet
10 Central heating flowoutlet
11 Central heating return inlet
14Safetyvalve
16Fan
19Combustion chamber
20Burner assembly
21Maininjector
22 Burner
26Combustion chamber insulation
27Copper heat exchanger for central
heating and domestichot water
28Fluecollector from heat exchanger
29Internal flueexit
32Central heating pump
+
-
R
OVER RIDE
12:31
x
x
4
AUTO P
OI
P
STEP
STEP
OUTIN
bar
4
3
2
1
bar
0
OFF RESET
ON
60
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
4318729
5
28
90
132
49
22 82 81
20
21
114
34
42
50
91
16
34Central heating flow
temperature sensor
36Automaticairvent valve
42Domestichot water flow
temperature sensor
43Airpressure switch
44 Gas valve
49Safetyoverheat thermostat
50Central heating flowlimitthermostat
56Expansion vessel
62Time clock
63Central heating
temperature adjustment
81Ignition electrode
82Sensor electrode
84Primarygas valvesolenoid
85Secondarygas valvesolenoid
*90Fluegas test point
*91Airtest point
98On/Off/Reset switch
114Lowwater pressure cutoff switch
132Fluegas deflector
136Flowmeter
145 Central heating pressure gauge
157Domestichot water temperature
adjustment
187Fluediaphragm
189Indication lackofflame
190Indication lighted burner
*For use withfluegas analyser

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2.04 Central heating adjustment (not normally required)
To adjust boiler heat input (thusalso regulatingheat output to the central heatingwater) simply adjust the main burner
via the electroniccontrol board (fig. 4, 5and see paragraph 5.04 page 24).
The diagramsindicate the variation in heat output to the water asburner workingpressure isvaried.
Adjustingboiler output to the actual requirementso ft he central heatingsystem will minimise boiler cyclingt hussavingfuel,
varyingthe output hasvirtually no effect on the efficiency and combustion characteristics ofthe 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
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
m
b
ar
18 19 20 21 22 23
10
15
20
25
30
35
9 1011121314151617
91011121314 18192015 16 178
2.05Domestichot water variabilitycharacteristics
The temperature ofthe domestichot water can
be varied from 40 to 55°C by adjustingthe boiler
potentiometer.
Diagram of domestichot water production
0 345678910111213141516
39
40
45
50
55
60
65
Temperatura di erogazione sanitaria °C
Portata sanitaria dm /min.
Potenza caldaia scambiata
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
kcal/h x1000
3
Temp. entrata acqua sanitaria 15 °C
Temperature of domestichot water intake 15°C
Flow of domestichot water L/min
Temperature of domestichot water supply°C
Boiler output exchanged kcal/hx1000
Fig. 6

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Fig. 8
Pressure loss diagram
SIZING OF ADDITIONAL EXPANSION VESSELS:
Deduct from the value given in the table the 8litre
vessel supplied.
Note:
1. Fill C.H.installation to min. 1.5bar.
2.Select the expansion vessel for asystem
pressure of 2.0bar.
3.Expansion vessel must be fitted to central
heating return pipe.
4.The standard 7litre expansion vessel is
charged to 1bar.
5.The additional expansion vessel should be
charged to 1bar.
SAFETY VALVE
SETTING(bar)
VESSEL CHARGE
PRESSURE (bar)
INITIAL SYSTEM
PRESSURE (bar)
TOTAL WATER
CONTENTofSYSTEM
3.0
0.51.01.5
1.01.52.01.52.02.0
EXPANSIONVESSEL VOLUME (litres)
LITRES
253.56.513.74.710.38.3
507.012.927.59.520.616.5
7510.519.441.314.230.924.8
100 14.025.955.119.041.233.1
12517.532.468.923.751.541.3
15021.038.8 82.628.561.8 49.6
17524.545.396.433.272.157.9
200 28.051.8 110.238.082.466.2
0.1400.2590.551 0.1900.4120.33
For syst.volumes other than
those givenabove,mult.the syst.
volume bythe factor across
m |h
3
Q
8
7
6
5
4
3
2
1
00.5 1.5 2.512
H
mbar x 100
2.06 Pumpcharacteristics
The pump head available for circulating the water is given in fig. 7.
N.B.-The pump is factoryset at position 3.The pump is aGrundfos
type 15-50UPS series.
Grundfos Pumpperformance graph
Note -Minimum flowthrough boiler heat exchanger at anytime
should not fall below6litres per minute.
Ifthe total volume of water in the system exceeds 40litres an
additional expansion vessel must be fitted to the central heating
return pipe.
Fig. 7
1 2 3 Speed settings
ABoilerspressuredrop
BAvailablepumpheadC.H.

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3. INSTALLATION DETAILS
Gas Safety (Installation & Use) Regulations: 1996
In the interest of safety, it is the lawthat all gas appliances are installedby a competent person in accordance with the
above Regulations, BuildingRegulations/BuildingStandards Scotland, Codes of Practice, current I.E.E. Regulations and
the byelaws of the LocalWater Undertaking. Failure to comply with the Regulations may leadto prosecution;it is your
responsibility to ensure that the lawis compliedwith.
N.B. For Northern Irelandthe rules in force apply.
Important -If the boiler is to be fittedin a timber framedbuildingit should be fittedin accordance with the Institute of Gas
Engineers document IGE/UP/7.If in doubt advice should be sought fromthe LocalSupplier.
Location of Boiler
The installation of the Falcon must be on a suitable non-combustible loadbearingwall which will provide an adequate
fixingfor the boiler mountingbracket assembly.The location should be in an area where the water pipes will not be
subjectedto frost conditions.In sitingthe combination boiler the followinglimitations must be observed:
The combination boiler may be installedin any roomor internalspace, although particular attention is drawn
to the requirements of the current I.E.E. wiringregulations andin Scotlandthe electricalprovisions of the
buildingregulations applicable in Scotland, with respect to the installation of the combination boiler in a room
or internalspace containinga bath or shower.
Where a roomsealedappliance is installedin a roomcontaininga bath or shower any electricalswitch or
appliance controlutilisingmains electricity must be situatedso that it cannot be touchedby a person using
the bath or shower.
AirSupply
The roomor compartment in which the boiler is installeddoes not require a purpose providedvent when
usingthe standardconcentricflue.
Flue System
The boiler allows the flue outlet to be taken fromthe rear of the boiler, fromeither side or vertically.
Astandardflue length of 0.75metres is provided. Alternative lengths of two or three metres can be supplied
(equivalent to wall thicknesses of up to 565, 1815 and2815mm for rear flues, deduct 91mm plus distance from
side wall for side outlet flues).It is absolutely essential, to ensure that products of combustion dischargingfromthe
terminalcannot re-enter the building, or enter any adjacent building, through ventilations, windows, doors, naturalair
infiltration or forcedventilation/air conditioning.
Gas Supply
If necessary the localGas supplier should be consulted, at the installation planningstage, in order to establish
the availability of an adequate supply of gas.
An existingservice pipe must not be usedwithout prior consultation with the LocalGas supplier.
Agas meter can only be connectedby the LocalGas supplier, or by a LocalGas suppliers Contractor.
Installation pipes should be fittedin accordance with BS6891-1988.
Appliance inlet workingpressure must be 20mbar MINIMUM, for NGand37mbar minimum for LPG.
Pipeworkfromthe meter to the combination boiler must be of an adequate size.
The boiler requires 2.73m3/h of naturalgas, and2,00 kg/h of LPG.
Do not use pipes of a smaller size than the combination boiler inlet gas connection.
The complete installation must be testedfor gas soundness andpurgedas describedin BS6981-1988.All pipework
must be adequately supported. An isolatinggas valve is providedandshould be fittedon the boiler gas inlet.Please
wait 10 minutes when lightingfromcold before checkinggas rate.Gas pressures should be checkedafter the boiler has
operatedfor 10 minutes to reach thermalequilibrium.
WaterSystem
Note -the boileris designedforsealedsystems only andmust NOT be usedon open ventedsystems.

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Fig. 9
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. 9.
Important -If thermostatic radiator vales are fitted a bypass must be fittedtoensure a minimumflowrate throughthe
boiler of6l/min. The bypass should be fitted as far as possible from the boiler.
Make UpWater
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. 10.
DomesticHot 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.). Ifthe coldmainssupplyexceeds 5bar (72 P.S.I.), a water governor or pressure reducing valve must be
fittedby 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
Gas
Cold water Additional expansion
vessel C.H.
(if required)
Filling
point
C.H.
Bypass
NOTE: A bypass must be fitted as far as possible from
the boiler if thermostatic radiator valves are fitted
thoughout.
Key
1. Filling point C.H.
2. Temporary connection
3.Coldwater supplyFig. 10

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Terminal Position
POSITION MINIMUM SPACING mm
ADirectly below an openable window, air vent, or any other ventilation opening 300
BBelow gutters, soil pipesor drainpipes75
CBelow Eaves100
DBelow a Balcony 100
EFromvertical drainpipesor soilpipes75
FFrominternal or external corners100
GAbove adjacent ground or balcony level 100
HFroma surface facing the terminal 600
IFacing another terminal 1,200
JFromopening (door/window)in carport into dwelling 1,200
KVertically froma terminal on the same wall 300
LHorizontally froma terminal on the same wall 300
NBelow carport 600
AQuinnel Barrat and Quinnel guard (part.No.C2)should be screwed to the wall centrally over the terminal, when
the terminal height isless than 2mfromfloor level.
Fig. 12
CLEARANCES:
*600mm minimumclearance for servicing access
Fig. 11
400 5 min.5 min.
100 min.860
360 50 mm
600* min.
720
200 min.

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3.01 Drilling Template (Top Flue Application)
Select suitable mounting position for boiler, using the template mark flue outlet and boiler mounting points. Drill two
10mm holes 90mm deep to accept the wall plugs, fit wall plugs. Fit two special wall plugs on the wall as described in
the fig. 13a. Fasten the wall 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 hotwateroutlet
4.Gassupply
5.Domestic hotwaterinlet
6.CH returnFig. 13b
15 min
5 min
Ø 118
195.5
215
400
15 min
Ø3/4''Ø3/4'' Ø1/2''Ø1/2''Ø1/2''Ø1/2''
101.5
380
200 min
219 min
909 min 204.5 min
132456
20
360
Fig. 13a

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3.02 Restrictor
For boiler operation, the restrictor supplied with the unit must be mounted following the instructions below.
Determine the correct size of flue restrictor required. Before inserting the flue gas duct in the boiler, check that the
restrictor fitted is correct and that it is correctly positioned (see fig. 14).
N.B.:the diameter ofthe hole is stampedon
the restrictor
Boiler is fittedwithØ45 restrictor as
standard
Holes Ø : 45 47 50
Ø
Fig. 14
CHOICE OF R ESTRICTOR:
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
suitable restrictor for the flow resistance calculated
RESTRICTOR FOR CONCENTRIC SYSTEM
Flue lenght up to:
Use
restrictor
size
Concentric
60 / 100
1 bend + 1 meter 50 mm
1 bend + 3 meters No restrictor
Concentric
80 / 125
1 bend + 3 meters 45 mm
1 bend + 4 meters 50 mm
1 bend + 5 meters No restrictor

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A 90° bend (fig. 16) is supplied for the horizontal connection of air and flue gas pipes. This can be oriented
towards the chosen wall in degrees of 45°.
3.03 Top Outlet Concentric Flue Connection
3.03.1 Vertical concentric connection
L
A=L+(85-90)mm
Ø2
Ø1
25-30 mm 60
Ø2
Ø1
Ø1=100 Ø2=60
Fig. 16
Trimthe 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 extremelyeasyand safe option.
Fig. 15
Concentric
Vertical
Connector
3.03.2Horizontal concentric connection

16
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Fig. 17
Notes on concentric horizontal installation
To locate the centre of the hole for passing the
pipes through the wall, refer to fig. 13. Bear in
mind that the two concentric pipes must slope
downwards away from the boiler at a rate of about
3 mm/m to avoid rainwater entering the boiler. The
concentric pipes making up the air - flue gas duct
must be sealed with the gasket where they join
the boiler (fig. 17). Outside, the pipes should
protrude from the wall between 10 and 60 mm
(fig. 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 3.02for use of restrictor
Maximum flue lenght permissible 100 mm concentric 125 mm concentric
Vertical Horizontal* Vertical Horizontal*
Falcon 4 m 3 m 5 m 5 m
Reduction for bend
100 mm concentric bend 90° 1 m
100 mm concentric bend 45° 0,5 m
125 mm concentric bend 90° 0,5 m
125 mm concentric bend 45° 0,25 m
*For horizontal Flueingthe reduction for appliance bendor turret are already included.
21 3
max. 3 m
2
1
max. 4 m
4
3
Fig. 18a Fig. 18b

17
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Fig. 19
3.04 Top Outlet: Two Pipe Flue System
3.04.1 Two pipe connection
Two separate ducts Ø80 for air intake and flue
gas discharge can be directly connected to the
boiler. Fit separate air intake plate.
Connect flue duct to central hole Ø80 and air
duct to left or right air intake hole Ø80. Leave blanking plate "2" in remaining air intake. Awide number of accessories
for two pipe systems are available fromFerroli (ref. to page 18). Before installing your systemplease check via calculation
table (3.04.2) you are not exceeding the maximumpermissible length for the appliance.
Notes on two pipe system installation:
When using the two pipe systemthe flue discharge pipe must have a 25mm air gap when passing through combustible
materials. Where the flue discharge pipe passes through the airing space of an airing cupboard it must be protected
by a non combustible guard or expanded metal giving an annular air gap of at least 25mm. Where the flue discharge
pipe passes through a wall containing cavity insulation,a non combustible sleeve must be fitted. Additionally a gap of
25mm between the sleeve and the insulation should be provided by cutting back the insulation or packing loose fill
bead insulation with mineral fibre. Where the flue pipe is run through an unheated roof space it should be insulated
with non combustible insulating material to prevent condensation. The flue pipe should be supported at intervals of not
more than 1.8mand the support should be preferably below a joint.
3.04.2Two pipe flue system
•Calculatingmaximum permissible flue length.
The calculation method is based on a standard reference parameter (1 metre of horizontal air flue 80 diameter 80)for
the maximumlength 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 xmetre of horizontal air induction pipe is indicated. For every boiler
model a maximumpipe length is provided,expressed in nmetres of horizontal air pipe. In this way,to calculate
the length of a proposed 2pipe air-flue system,add the flow resistance (reduction)in equivalent metres-air. For
every component and fitting present in the system,and to check that the total is less than the maximumlength
the permissible for the boiler model.
MPORTANT: the pipes and fittings flow resistance (reduction) have beensummarised onthe following pages. The
flow resistance values writtenrefer only to Ferroli pipes and fittings.
CALC ULATION ROUTINE
1. Utilise the pipes and fittings flows resistance tables on the following pages and calculate the total flow resistance in
metres-air,by adding the flow resistances of the components in the whole air-flue system,based on their position
(vertical or horizontal,air inlet or flue outlet).
Please note that the same fitting,identified by a one code (i.e. 1pipe diameter 80,code KWMA83A),can offer
different flow resistances if positioned as air inlet or flue outlet,if placed vertically or horizontally.
The flow resistance ofthe special two pipe flue-airadapters do not have to be includedin the calculation as they
are already includedin the maximum lengthcalculation.
2. For the restrictors,please refer to cap. 3.02to determinate the correct diaphragm.
3. Check that the total flow resistance calculated is less or equal to 48 metre,the maximumpermissible for Falcon.
Ø80Ø80
AIRFLUE
1
2
Insert blankingplate 2
in remainingairintake
Remove
blanking
plate

18
F LCON
3.04.2 (continued)
Tab. 1 - Pipes and
fittings reduction table
Air Flue
Vertical Horizontal Vertical Horizontal
Description
Male-female
flue Ø80
Female-female
bend 45° Ø80
Female-female
bend 90° Ø80
Male-female
bend 90° Ø80
Pipe fitting M/M/F Ø80
with inspecting
plug+trap for
condensate drainage
system
Description
Air terminal of
inlet protection Ø80
Outlet flue air inlet
for concentric system
Ø80
Pipe fitting for
outlet flue Ø80
Outlet flue air inlet for
connection with split end
Ø80
1112
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
Male-female
bend 90° Ø100
Air wall terminal
products of
combustion Ø100
Air terminal
of outlet
protection
Ø100
0,4 0,4 0,4 0,8
0,6 1
0,8 1,3
3
1,5
A
c
c
e
s
s
o
r
i
e
s
Ø
1
0
0
Spigot and
socket
reduction
Ø 80/100
1,5 3

19
F LCON
For further accessories please refer to:
"Flue system manual for room sealed boiler"
Attention: flow resistance (reduction) equivalent
included between 38 and 48 (see table on page 14)
Remove the flue diaphragm.
The flue and air pipes must have an inclination down-
ward equal to 3% from boiler to outside.
Example of calculation for wall inlet/outlet
with 2pipe system
maximum total flue length: 48 metres
7
4
6 325 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
2pipe 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. 21
Fig. 23Fig. 22

20
F LCON
3.05 Connecting the central heating and domestic hot water circuits
Connect to the relevant connections as indicated in fig. 1.
Connect the pressure relief valve discharge pipe (15mm) to the outside of the building, where possible over a drain.
The discharge must be such that it will not be hazardous to occupants and passers-by or cause damage to external
electric components or wiring. The pipe should be directed towards the wall.
To ensure long life, the heating circuit should be correctly sized and fitted with all the controls necessary to ensure
correct functioning and operation. The differential between the boiler flow and return pipes should not be more than
20°C. You are advised not to use the boiler with return temperatures of less than 50°C in order to prevent patches of
condensation forming and having a corrosive effect on boiler components.
3.06Boiler water characteristics
If the water is harder than 18clarke degrees, the water used should be treated to avoid possible scale in the
boiler caused by hard water or corrosion by aggressive water. It should be remembered that as a result of its low
thermal conductivity, even scale of just a few millimetres thickcan lead to considerable overheating of the boiler
walls, resulting in serious problems.
IT IS ABSOLUTELY VITAL THAT THE WATER USED IS TREATED IN THE FOLLOWING CASES:
a) Extensive systems (containing large quantities of water);
b) Frequent additions of water to top-up the system;
c) Domestic hot water circuits
If the system requires partial or total emptying, you are recommended to refill it with treated water.
3.07Filling
When cold, system pressure should be about 1 bar. If while running venting off of air dissolved in the water causes the
pressure of the central heating system to drop below the minimum level described above, the user must utilise a filling
loop to bring it backto the original value. During operation, water pressure in the boiler 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 checkvalve should be fitted
in the flow to prevent gravity circulation around the heating system.
3.08Gas connection
Gas connection should be carried out using a rigid pipe.
The flow at the gas meter should be sufficient for the simultaneous use of all appliances connected to it. Connect the gas
supply to the boiler according to current regulations. The diameter of the gas tube leaving the boiler is not the determining
factor in choosing the diameter of the pipe between the appliance and the meter. This must be selected in relation to
length and pressure drop and in any instance should not be less than 22mm.
The whole ofthe gas installation including the meter should be inspected and tested for soundness and purged
in accordance with BS6891-1988.
N.B. -The filling loop will be fitted by the installer at the time of installing the system. It is NOTa part
ofthe boiler.
3.09Electrical connection
The boiler must be connected to a single phase 230 V50 Hz electricity supply with a 3Amax. fuse and a bipolar switch
with contact opening of at least 3mm fitted between the boiler and the electricity supply. The boiler must always be
connected to an efficient earth installation. Under the electrical box, there is a 3pole terminal board for connecting
the boiler to the mains (230 V50 Hz) and a 2 pole board for connecting a room thermostat (RT). To connect, undo
the screws fixing the terminal board box and connect the wires, ensuring correct polarity of the terminals. It should be
noted that there is low voltage (24V) between the room thermostat contacts.
When the boiler is connected to an electricity main, it is essential TOOBSERVE CORRECT POLARITIES (LIVE: brown
cable, NEUTRAL: blue cable, EARTH: yellow-green cable).
All wiring must conform to current I.E.E. regulations.