Ferroli PEGASUS F2 T User manual

HIGH EFFICIENCY GAS-FIRED
CAST-IRON BOILERS
PEGASUS F2 T
Models 51 - 68 - 85 - 102
INSTALLATION
AND MANINTENANCE INSTRUCTIONS
Appr. Nr. A 9503 T - 0085 AQ 0765

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Contents
1. General technical data
2. Dimensional and technical characteristics
3. Installation
4. Wiring diagrams
5. Startup and shutdown
6. Gas regulation and conversion
7. Maintenance and cleaning
8. Fault finding

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1. GENERAL TECHNICAL DATA
1.01 Introduction
The Pegasus F2 T, with CE approval, is a designed foruse with NATURAL GAS (G 20) or LPG (G 31)
for indirect central heating and hot water.
1.02 Installation requirements
Only CORGI registered installers should fit the Pegasus boilers.
TheboilerinstallationshouldcomplywithrelevantBritishstandardsspecifications,codesofpractice,
and current building Regulations, together with any special regional requirements of the local
authorities, gas supplier and insurance companies.
2. DIMENSIONS AND TECHNICAL DATA
2.01 Dimensional data (see fig. 1 and table 2)
Fig. 1
a1 - Return 1 1/2”
a2 - Flow 11/2”
a3 - Gas inlet 3/4”
a2
C
E
D
a1
a3
222.5
672.5
762.5
900
B
A
1000

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2.02 Technical data
The standard cast-iron PEGASUS F2 T boiler is set to operate on NATURAL GAS (G 20).
Tgned to operate with a flow temperature of 82°C and a maximum ∆t of 20°C. The limit thermostat
is adjustable up to a maximum of 110°C.
Table 3
MODEL GAS FLOW RATE
PILOT
INJECTOR
fl mm
0,24
0,24
0,24
0,24
LPG G31
0,4
0,4
0,4
0,4
Nat. Gas G20
No. of
MAIN
BURNER
BARS
3
4
5
6
GAS SUPPLY
PRESSURE
mbar
GAS PRESSURE AT
BURNER MANIFOLD
mbar
5,9
7,9
9,9
11,8
Nat. Gas G20
m
3
/h
4,34
5,79
7,24
8,68
LPG G31
kg/h
15 to 23
15 to 23
15 to 23
15 to 23
Nat. Gas G20
37
37
37
37
LPG G31
13,3
13,3
13,3
13,3
36
36
36
36
LPG G31
Pegasus F2 51 T
Pegasus F2 68 T
Pegasus F2 85 T
Pegasus F2 102 T
MODEL DIMENSIONS CONNECTIONS
Table 2
A
mm
550
640
720
800
B
mm
96,5
96,5
106,5
106,5
C
fl mm
180
180
200
200
D
mm
43
46
44
42
E
mm
35
38
36
34
RETURN
a1 fl
11/2"
11/2"
11/2"
11/2"
WATER
CONTENT
litres
22
26
30
34
MAX
WORKING
PRESS.
bar
4
4
4
4
WEIGHT
INCLUDING
PACKAGE
Kg.
Pegasus F2 51 T
Pegasus F2 68 T
Pegasus F2 85 T
Pegasus F2 102 T
11/2"
11/2"
11/2"
1 1/2"
FLOW
a2 fl GAS
a3 fl
3/4"
3/4"
3/4"
3/4"
MODEL
Table 1
Pegasus F2 51 T
Pegasus F2 68 T
Pegasus F2 85 T
Pegasus F2 102 T
NUMBER OF
SECTIONS
4
5
6
7
HEAT INPUT
(GROSS)
kW
62,2
83
103,8
124,3
HEAT INPUT
(NET)
kW
56
74,8
93,5
112
HEAT OUTPUT
kW
51
68
85
102
MAIN
INJECTOR
fl mm
2,15
2,15
2,15
2,15
LPG G31
3,5
3,5
3,5
3,5
Nat. GAS G20
260
300
350
400
Nat. Gas G20

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12356
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Control panel
Fig. 2b
Front view of the boiler without door
Fig. 2a
Key
1. Temperature-pressure gauge
2. Boiler control thermostat
3. Boiler on/off switch
4. Flue gas re-set thermostat
5. Electronic panel (nto available)
6. Control panel
7. Gas valve
8. Limit thermostat re-set
1 2
3
11
13
7
812
10
6
515
9
14
4
2.03 Main components
9. Pilot burner
10. Burner manifold
11. Gas pressure test point
12. Piezo igniter
13. Automatic air vent
14. Drain cock
15. Flue gas sampling point

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Fig. 3
2.04 Characteristic pressure drop curve
Water pressure drop in all models is shown in fig.
3.The followingdiagram showsthe pressuredrop
in the boiler as a function of the water flow rate.
12345678910
10
20
30
40
50
60
70
80
90
4 EL.
100
5 EL.
6 EL.
7 EL.
∆P mbar
Q m
3
/h
200
Flow rate
2.05 Safe discharge of combustion products
- TheboilercomeswithaFLUEGASDISCHARGETHERMOSTAT,whichprovidesahighlevelofsafety
and control over the discharge of combustion products. This thermostat cuts off the supply of gas to
the burner in the event of a faulty flue draft.
- If the FLUE GAS DISCHARGE THERMO-
STAT has been activated, you should un-
screw the control panel protection cover
(partno.4infig.2aand2b)andmanually
“reset”thethermostat.Afterthat,theboiler
will return to normal operation.
- If the FLUE GAS DISCHARGE THERMO-
STAT needs to be replaced, use original
manufacturer’s parts only and make sure
the electric connections and positioning
of the bulb (see fig. 4) are correct; NEVER
UNDER ANY CIRCUMSTANCES LEAVE
THE FLUE GAS DISCHARGE THERMO-
STATDISCONNECTEDFROMTHEELEC-
TRIC CIRCUIT.
- In case of frequent switching off of the
thermostat, contact qualified personnel
only.
- During cleaning of the draft diverter, be
carefulnottodamagethethermostatphial.
Phial of flue gas
discharge thermostat
Boiler rear view
Fig. 4

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3. BOILER INSTALLATION
(To be performed by qualified personnel only)
3.01 General warnings
The boiler should be installed according to current regulations. (see para 1.02)
Wesuggest fittingisolatingvalves between theboilerand theheatingsystem toisolatethe boilerfrom
the system if necessary.
The rise in temperature of the heating water (the difference between the water flow and return
temperatures) should not exceed 20°C. This is to prevent possible damage caused by condensation
forming in the boiler.
Combustion products should be discharged through a flue with a cross section in accordance with
current standards and in any not less than the boiler flue outlet connection.
Connect the gas supply to the boiler in accordance with current regulations. The diameter of the gas
connectionentering theboiler doesnot dictatethe choiceof diameterfor thepipe betweenthe boiler
and the gas meter which should be selected based upon the pipework lecgth and pressure drop.
Connect the boiler to a single-phase 230 V ~ 50 Hz power supply through a standard terminal block
or outlet, with 2A max. fuses connected between the boiler and the power line.
3.02 Boiler water characteristics
When the water supply has a high hardness, it should be treated before entering the heating system
topreventbothscaling(causedbyhardwater)andcorrosion(causedbyaggressivewater)intheboiler.
Please remember that because of their low thermal conductivity, even small scales just a few
millimetres thick cause the boiler walls to overheat considerably with serious consequences.
You must treat the water used for the heating system in the following cases:
A) Very large systems (with large volumes of water).
B) Systems where partial or complete draining - and water refilling - are frequent.

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4. WIRING AND CONNECTIONS DIAGRAMS
- Electrical connections should be performed according to the diagrams shown below.
- Connecttheboilertoasingle-phase,phaseneutral,230V~50Hzpowersupplythroughastandard
terminal block or outlet with 2A max. fuses connected between the boiler and the power supply.
Remember that the boiler should always be provided with a good earth.
IMPORTANT: The manufacturer disclaims any liability for damage to property or persons caused by
failure to earth the boiler correctly.
Electrical connections diagram
Fig. 5
Key
IC - Boiler ON/OFF switch
TA - Room thermostat
TR - Control thermostat
TF - Flue gas thermostat
VG - Gas valve
TS - Limit thermostat manual re-set
F - Thermocouple interruptor
CA - Auxiliary contact
Note: Dotted lines indicate connections to be performed during installation.
230V
50Hz
3
113
2
4
IC
24
N
VG
L
TS
F
5
8
7
6
9
TA
CA
10
38910756421
230V ~
NL
50Hz
TS
IC
43
21
F
VG
TA CA
TR
TF TR
TF
General wiring diagram

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4.02 Access to the internal components of the control panel
Foraccesstotheterminalblockandtheinternalcomponentsofthecontrolpanel,proceedasfollows:
a - Switch off the power supply to the boiler.
b - Lift off the boiler cover (held in place by slot pins).
c - Unscrew the four screws that hold the plastic panel against the side of the boiler .
d - Rotate the panel to the front to its locked position.
e - Carry out the work and reassemble in reverse order.
4.03 Exploded view of the control panel (fig. 6)
Key
1. Control panel
2. Wiring harness protection plate
3. Terminal block
4. Temperature-pressure gauge
5. Control thermostat
6. Boiler on/off switch
7. Flue gas thermostat re-set
Fig. 6

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Key
1 Gas valve control knob
2 Burner pressure regulating screw
3 Incoming gas pressure test point
4 Outgoing gas pressure test point
5 Pilot light adjusting screw Fig. 7a
HONEYWELL V4600C
5. STARTUP AND SHUTDOWN
5.01 Checks to be carried out on initial lighting
It is good practice to check the following on initial lighting: that the cutoff valves between the boiler
andheatingsystemareopen;thatalliswellpressurizedandvented;thattherearenogasorwaterleaks
from the water system or boiler; that the electrical connections are correct and the earthing cable
connected to a good earthing system; that there are no inflammable liquids or materials in the
immediate vicinity of the boiler and that the flue is not blocked.
5.02 Startup with the HONEYWELL V4600C valve in models 51-68 (fig. 7a)
Set the boiler control thermostat 2 (fig. 2) to minimum. Switch off the electrical power.
Open the gas cock upstream from the boiler.
Release the air held in the gas pipes by opening the incoming gas valve test point marked with the
number 3 (fig. 7a).
Press and keep pressed the gas valve control knob 1.
Ignite the pilot burner by repeatedly pressing the piezoelectric ignition button 12 (fig. 2).
Oncethepilot light hasbeenignited,keepthe gasvalve knobpressedforanother15 -20 secondsand
then release it slowly checking that the pilot light remains lit. If it does not, wait 30 seconds before
igniting it again.
Power up the boiler electric circuit (control thermostat and electrical power).
Set the boiler control thermostat 2 (fig. 2) to the desired temperature (no less than 50°C).
At this point the main burner should ignite and the boiler operate automatically.

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5.03 Startup with the HONEYWELL V4400C in models 85-102 (fig. 7b)
Set the boiler control thermostat 2 (fig. 2), to minimum. Switch off electrical power.
Open the gas cock upstream from the boiler.
Release the air held in the gas pipes by opening the incoming gas valve test point marked with the
number 3 (fig. 7b).
Press and keep pressed the gas valve control knob “A”.
Ignite the pilot burner by repeatedly pressing the piezoelectric ignition button 12 (fig. 2).
Oncethepilotlighthasbeenignited, keep thegasvalve knob pressedforanother 15-20 seconds and
then release it slowly checking that the pilot light remains lit. If it does not, wait 30 seconds before
igniting it again.
Switch on boiler.
Set the boiler regulating thermostat 2 (fig. 2) to the desired temperature (no less than 50°C).
At this point the main burner should ignite and the boiler operate automatically.
Key
1 Ignition button
2 Gas pressure regulating screw
3 Incoming gas pressure test point
4 Pilot light adjusting screw
5 Shutdown button
HONEYWELL V4400C VALVE
Fig. 7b

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5.04 Temporary shutdown
To turn the boiler off for a short period of time, simply switch off the power supply (using the boiler
switch). All electrical elements are thus turned off and only the pilot light remains lit.
5.05 Long-term boiler shutdown
Turnknob1asindicatedinfig.7a-7b(inmodels51-68),pressbutton5asindicatedinfig.7c(inmodels
85-102).This turnsoff theflowof gasto boththe mainburnerand thepilot light.Turn off thegas cock
upstream from the boiler and switch off the power supply.
5.06 Inspections and controls after startup
At first startup:
- Make sure the gas circuit is perfectly leakproof.
- Make sure the pilot light is adequate and well adjusted; if it is not, adjust it using the gas valve
adjusting screw (fig. 7a-7b-7c).
- Test boiler ignition by starting it and turning it off using the regulating thermostat.
- Checkthat nocombustion gasescapes fromthe rearof theboiler atthe heightof thedraft diverter,
indicating that either the flue is blocked or the draft is insufficient.
- Checkthatthepipeconnectingtheboilertotheflueisperfectlyleakproofatthepointofconnection
between the flue and the boiler.
- Check that gas consumption, measured by the gas meter, matches that indicated in the technical
data table.
6. REGULATING
6.01 Adjusting the pressure at the burner
As described above, the boiler is set up to operate on NATURAL GAS (G 20); gas pressure has been
tested and calibrated by the manufacturer.
However, due to possible differences in pressure in the gas supply system, at first startup you should
check and if necessary adjust the pressure at the injectors to match the pressure level shown in table
3 of the technical data (page 5). Test pressure at test point 11 fig. 2a/2b.
6.02 Gas pressure adjustment and gas conversion with the “HONEYWELL V4600C” valve
Adjusttheburnerpressureatthemainburnersbyturningscrew2(fig.7a):turnitclockwisetoincrease
the burner pressure and anticlockwise to decrease it. (burner pressure test point 11 fig. 2a/2b.
Thepilotlightmaybeadjustedbyeye,withouttheuseofinstruments,bycheckingthattheflamecorrectly
envelopes the thermocouple without burning excessive gas. To adjust the flame, turn screw 5 (fig. 7a).
ToconverttheboilerfromNATURALGAStoLPG,besidesreplacingtheinjectorsyoushouldcarefully
set the pressure regulating screw 2 all the way in.

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Fig. 8
6.06 Pilot burner assembly
5
33-4 mm
4
7
Key
1 Burner plate
2 Pilot light viewing cover
3 Pilot burner
4 Ignition electrode
6.04 Gas pressure adjustment and gas conversion with the “HONEYWELL V4400C” valve
Adjusttheburnerpressureatthemainburnersbyturningscrew2(fig.7C):turnitclockwisetoincrease
the pressure and anticlockwise to decrease it. (burner pressure: test point 11 fig. 2a/2b).
The pilot light may be adjusted by eye, without the use of instruments, by checking that the flame
correctlyenvelopes thethermocouple withoutburningexcessive gas.To adjustthis flame,turnscrew
5 (fig. 7C).
ToconverttheboilerfromNATURALGAStoLPG,besidesreplacingtheinjectorsyoushouldcarefully
set the pressure regulating screw 2 all the way in.
REMEMBER: The complete LPG conversion kit is supplied on request only.
6.05 Replacing the main and pilot burner injectors.
Caution: The following adjustment and conversion operations are to be performed by qualified
personnel only.
To replace the main and pilot injectors proceed as follows:
Turn off the gas and switch off the power supply to the boiler.
Replacethemainandpilotinjectortakingcarenottodamagethemaininjectorssealinggaskets.Ifthey
have been damaged, replace them.
Re-assemble with care.
Adjust the gas pressure at the main injectors, and the pilot flame.
Check that the boiler functions properly and that there are no gas leaks.
5 Thermocouple
6 Pilot injector
7 Pilot gas supply

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7. MAINTENANCE AND CLEANING
Thefollowingoperationsaretobeperformedbyqualifiedpersonnelonly.Werecommendyoucontact
our local Customer Technical Support Centers.
7.01 Seasonal inspection of the boiler and flue
Before the beginning of winter you should perform a general inspection of the boiler, heating system
and flue. The inspection should verify:
That the boiler sections, burner and flue are clean.
That the water in the system is at the correct pressure.
That all control and safety devices operate properly.
That the thermocouple and ignition electrode are free of carbon deposits.
That the pilot flame correctly envelopes the thermocouple.
That circulation pumps are free running.
That there gas leaks.
That the gas flow rate and pressure are correct.
7.02 Cleaning the boiler and the flue
To clean the boiler and the flue, remove the burner unit from the boiler.
Foraccess to the cast-iron heatexchanger, proceedas follows(fig. 9):Remove thecover ofthe casing
secured by slot pins; pull out the insulation covering the draft diverter, remove the flue collector
inspection cover 2 and its insulation, secured with self-tapping screws 1.
Nowyoumaycleanallthefluegaspassagesintheboilerusingabrush3.Rememberyoushouldcheck
and if necessary clean the flue and its connection to the boiler. Be careful not to damage the flue gas
thermostat phial or capillary.
Important - Do not clean the burners with chemicals or a steel
brush, as these might change the air-gas mixture outlet holes.
When cleaning is complete, re-assemble carefully and in the
correct position. Then check the seal along the gas and flue gas
circuits, functioning of the control and safety devices and gas
pressure and gas flow rate.
Key
1 Securing screws
2 Inspection cover with insulation
3 Cleaning brush
4 Flue gas sampling point Fig. 9
1
2
4
3

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9. FAULT FINDING
Fault Cause and Corrective Action
No ignition spark Piezoelectric igniter failure.
Replace the igniter.
Spark electrode is broken or badly positioned.
Replace the electrode or position it correctly (see fig. 8).
Faulty contact between terminal and cable.
Screw the terminal tightly onto the igniter cable.
No pilot ignition No gas.
Open the gas cock.
Air is held in the pipes.
Vent it as described in the chapter on startup.
Pilot injector is clogged.
Clean the injector (with compressed air).
Gas flow rate is insufficient.
Adjust flow rate by turning the screw on the gas valve.
Poor pilot flame The flame has been adjusted wrongly.
Check that the gas inlet pressure is correct.
Pilot burner is dirty.
Clean the pilot burner (with compressed air).
Pilot light goes out Thermocouple is faulty.
Check and replace the thermocouple.
Insufficient flame.
Adjust the flame, turning the screw on the gas valve, until it
envelopes the thermocouple.
Loose contact with the gas valve.
Tighten the connection to the gas valve.
No ignition of main burner No power supply.
Switch the power on.
Nozzles are clogged.
Carefully clean the nozzles.
Gas valve is faulty.
Repair or replace gas valve.
Flue gas thermostat switched off.
Check the flue for any obstructions, then manually reset the
flue gas thermostat.
Instable main burner Lack of gas.
Check the gas pressure at the main burner.
Boiler is dirty.
Inspect and clean the boiler body.

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Remember - To avoid unnecessary expenses, before contacting Technical Support, make sure that
any boiler failure is not due to the absence of electric power or gas.
Burner is dirty.
Inspect and clean the burner.
Main burner burns poorly Flame is not adjusted properly.
Adjust the gas pressure at the main burner (see table 3 page 5).
Smell of unburnt gas Boiler is dirty.
Inspect and clean the boiler body.
Flue draft is insufficient.
Check flue draft.
Air ventilation is insufficient.
Increase ventilation in the room.
Flame has been adjusted too high.
Check the gas flow rate and gas pressure at the main burner.
No rise in temperature Flame is not adjusted properly.
while the boiler is working Check that gas consumption is correct.
Boiler is dirty.
Inspect and clean the boiler body.
Output is too low.
Check that the boiler model matches the heating system
requirements.
Control thermostat restarts high Control thermostat has broken down.
temperature differential Replace the thermostat.
Thermostat bulb is outside its sheath.
Check that the bulb is inserted in place.
Condensation in boiler Control thermostat is adjusted incorrectly.
Raise the thermostat temperature.
Gas flow is insufficient.
Check that gas flow conforms to data in table 3 (fig. 2).
Boiler becomes dirty quickly Flame is adjusted incorrectly.
Check that the main burner flame is adjusted properly and
that gas flow is in proportion to boiler output.
Boiler shuts off Flue gas thermostat switched off.
for no apparent reason Inspect the flue draft for obstructions, then reset the flue gas
thermostat manually.
Safety thermostat switched off.
The boiler water temperature has exceeded safe operating
temperature.

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LichfieldRoad, Branston Industrial Estate, BurtonUpon Trent,Staffordshire DE143HD
Tel. [phone] - Fax [phone]
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3540723/0 - 01/01