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.