Ferroli Pegasus F3 119 User manual

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INSTALLATION AND
MAINTENANCE INSTRUCTIONS
GAS-FIRED CAST-IRON BOILERS
WITH ELECTRONIC IGNITION
AND FLAME RECTIFICATION MONITORING
models 119 - 136 - 153 - 170 - 187 - 221 - 255 - 289
PEGASUS F3
Appr. nr. A95.03 / A08 - A18 - 03/96
CE 0085 AQ 0765

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Pegasus F3

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Pegasus F3
Contents
1. General technical data
2. Dimensions and technical data
3. Installation
4. Wiring diagrams
5. Startup and shutdown
6. Regulating
7. Fuel conversion
8. Maintenance and cleaning
9. Fault finding

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Pegasus F3
1. GENERAL TECHNICAL DATA
1.01 Introduction
ThePegasusF3, with CE approval,is a designed for usewith natural gas (G 20)or LPG (G 31) forindirect
central heating ahnd hot water.
1.02 Installation requirements
Only CORGI registered installers should fit the Pegasus boilers.
The boiler installation should comply with relevant British Standards Specifications, codes of practice,
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 Dimensions (see fig. 1 and table 2)
Fig. 1
a1 - Return 2"
a2 - Flow 2"
a3 - Gas inlet1" (models 119 and 136) - 1" 1/2 (models 153 to 289)
a2
C
E
D
a1
a3
222.5
672.5
355.5
F
B
A
1050

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Pegasus F3
2.02 Technical data
The cast-iron PEGASUS F3 boiler is set to operate on natural gas (G 20).
The boiler is designed to operate with a flow temperaure of 82°C and a maximum ∆t of 20°C
MODEL
DIMENSIONS CONNECTIONS
Tabla 2
Pegasus F3 119
Pegasus F3 136
Pegasus F3 153
Pegasus F3 170
Pegasus F3 187
Pegasus F3 221
Pegasus F3 255
Pegasus F3 289
A
mm
930
1020
1100
1190
1270
1440
1610
1780
B
mm
126
141
141
166
166
166
191
191
C
Ø mm
220
250
250
300
300
300
350
350
D
mm
46
49
55
58
56
57
58
59
E
mm
42
45
43
46
44
45
46
47
F
mm
1050
1050
1050
1050
1050
1050
1100
1100
1"
1"
1" 1/2
1" 1/2
1" 1/2
1" 1/2
1" 1/2
1" 1/2
GAS
a3 Ø
RETURN
a1 Ø
2"
2"
2"
2"
2"
2"
2"
2"
FLOW
a2 Ø
2"
2"
2"
2"
2"
2"
2"
2"
WATER
CONTENT
litres
38
42
46
50
54
62
70
78
MAX.
OPERATING
PRESS.
bar
4
4
4
4
4
4
4
4
WEIGHT
INCLUDING
PACKAGE
Kg.
WEIGHT
WITHOUT
PACKAGE
Kg.
0,24
0,24
0,24
0,24
0,24
0,24
0,24
0,24
LPG
G31
0,4
0,4
0,4
0,4
0,4
0,4
0,4
0,4
Nat.
G20
NUMBER
OF MAIN
INYECTORS
7
8
9
10
11
13
15
17
13,8
15,8
17,9
19,8
21,8
25,7
29,6
33,5
Nat. G20
m
3
/h
10,2
11,6
13,1
14,5
16,0
18,9
21,8
24,6
LPG G31
kg/h
15 to 23
15 to 23
15 to 23
15 to 23
15 to 23
15 to 23
15 to 23
15 to 23
Nat.
G20
37
37
37
37
37
37
37
37
G.P.L.
G31
13,3
13,3
13,3
13,3
13,3
13,3
13,3
13,3
Nat.
G20
36
36
36
36
36
36
36
36
LPG
G31
MODEL
HEAT
OUTPUT
HEAT INPUT
(NETT)
HEAT INPUT
(GROSS)
NUMBER OF
SECTIONS
8
9
10
11
12
14
16
18
kW
119
136
153
170
187
221
255
289
kW
131
149
168
187
206
243
280
317
kW
145,4
165,4
186,5
207,6
228,7
269,7
310,8
351,9
2,15
2,15
2,15
2,15
2,15
2,15
2,15
2,15
LPG
G31
3,5
3,5
3,5
3,5
3,5
3,5
3,5
3,5
Nat.
G20
470
530
575
625
665
760
875
945
410
465
510
555
595
685
795
860
Tabla 3 Table 1
MODEL
Pegasus F3 119
Pegasus F3 136
Pegasus F3 153
Pegasus F3 170
Pegasus F3 187
Pegasus F3 221
Pegasus F3 255
Pegasus F3 289
GS FLOW RATE
AT BURNERS
PILOT
INYECTOR
Ø mm
GAS SUPPLY
PRESS.
mbar
GAS PRESS. AT
BURNER MANIFOLD
mbar
MAIN
INYECTOR
Ø mm
Pegasus F3 119
Pegasus F3 136
Pegasus F3 153
Pegasus F3 170
Pegasus F3 187
Pegasus F3 221
Pegasus F3 255
Pegasus F3 289

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Pegasus F3
123568
4
Control panel
Fig. 2b
Front view of the boiler without front casing
Fig. 2a
Key
1. Temperature-pressure gauge
2. Boiler control thermostat
3. Ignition lockout reset botton
4. Limit thermostat-reset botton
5. Boiler on/off switch
6. Electronic panel (no available UK)
7. Ignition PCB
8. Control panel
9. Main gas valve
3
18
9
16
15
1
2
10
11
12
14
8
6
7
13
17
5
4
2.03 Main components
10. Incorporated security and Pilot light gas valve (ON-OFF)
11. Gas governor
12. Gas pressure switch (set to 5 mbar)
13. Burner manifold
14. Pilot burner complete with electrodes
15. Pressure test point (gas)
16. Drain cock
17. Flue gas sampling point
18. Automatic air vent

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Pegasus F3
3. BOILER INSTALLATION
(To be performed by qualified personnel only) See para 1.02
3.01 General warnings
The boiler should be installed according to current regulations.
We suggest fitting on-off valves between the boiler and the heating system to isolate the boiler from
the system if necessary.
The rise in temperature of the heating water (the difference between the water delivery and return
temperatures) should not exceed 20°C. This is so as to prevent possible damage caused by condensate
forming in the boiler.
Combustion products should be discharged through a flue with a cross section in accordance with
current standards (see UNI 9615) and in any case not smaller than that of the connection to the boiler.
Fig. 3
2.04 Characteristic pressure drop curve
Water pressure drop in all models is shown in fig. 3. The following diagram shows the pressure drop
in the boiler as a function of the water flow rate.
mbar
40345678910 20 30
Flow rate
600
500
200
300
400
60
70
80
90
100
20
30
40
50
14
18
89
16
10 11 12

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Pegasus F3
Connect the gas to the boiler in accordance with current regulations. The diameter of the boiler gas
inlet does not dictate the choice of diameter for the pipe between the boiler and the gas meter which
should be calculated based upon its length and pressure drop.
3.02 Boiler water characteristics
When the water supply has a hardness of more than 25 - 30 Fr., it should be treated before entering
the heating system to prevent both scaling (caused by hard water) and corrosion (caused by aggressive
water) in the boiler. 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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Pegasus F3
4. WIRING AND CONNECTIONS DIAGRAMS
- Electrical connections should be performed according to the diagrams shown here.
- Connect the boiler to a single-phase, phase neutral, 230 V ~ 50 Hz power supply through a
standard 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 good earthing.
IMPORTANT: If on use a 230 V room thermostat, it must be in II class.
The manufacturer disclaims any liability for damage to property or persons caused by
failure to earth the boiler correctly.
General wiring diagram
Fig. 4a
Note: Dotted lines indicate connections to be performed during installation.
Terminals L1, N1, 6 are reserved for connecting an electronic condensator (not available in UK)
The pilot light gas valve (part 118) also acts as a safety shut off valve.
Key
24 Spark electrode
25 Pilot burner
32 Pump
49 Limit thermostat (manual reset)
63 Boiler central thermostat
82 Ionisation probe
83 Ignition PCB
98 Boiler ON/OFF switch
114 Water flow pressure switch (not provided)
116 Gas pressure switch
117 Pilot light gas valve
129 Ignition lockout reset botton
160 Auxiliary contact
169 Suppression filter
L
230V
50Hz
10
9
7
1318114
116
3
1
98 2
169
4
14
129 1
12
11
C
4
5N1
L1 49
160
63
2
13
1461617
92537131 S 4561 B
HONEYWELL
15
83
32
X3
X6
X4
X5
3
1
4
2
118
16
20
19
22
24
25
117
82
18
17 21
2
3
42
6
N

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Pegasus F3
Electrical connections diagram
Fig. 4b
Note: Dotted lines indicate connections to be performed during installation.
Terminals L1, N1, 6 are reserved for connecting an electronic condensator (not available in UK)
The pilot light gas valve (part 118) also acts as a safety shut off valve.
Key
24 Spark electrode
25 Pilot burner
32 Pump
49 Limit thermostat (manual reset)
63 Boiler control thermostat
82 Ionisation electrode
83 Ignition PCB
98 Boiler ON/OFF switch
114 Water pressure switch (not provided)
116 Gas pressure switch
117 Pilot light gas valve
129 Ignition lockout reset botton
160 Auxiliary contact
169 Suppression filter
83
321
1
4
169
2
3
914567
S 4561 B
HONEYWELL
13 16
2
4
17
1
3
129
X4
X5
X6
X3 25 82
24
21
C
63
2019171615141211 219810 1813 22
49
116 160 117
118
32 LNNL
3
98
2
4
1
3514276
N1
L1
114
LN
230V
50Hz

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Pegasus F3
4.02 Access to the internal components of the control panel
For access to the terminal block and the internal components of the control panel, proceed as follows:
a - Shut off the power supply to the boiler.
b - Lift off the boiler cover (held in place by slot pins).
c - Unscrew the two screws that hold the plastic panel against the side of the boiler .
d - Rotate the panel all the way round to its locked position.
e - Carry out the work and reassemble in reverse order.
Caution: Be particularly careful when handling the electronic flame control unit (part. 4, fig. 5) and
its connections.
4.03 Exploded view of the control panel (fig. 5)
Key
1. Control panel
2. Wiring harness protective plate
3. Terminal block
4. Ignition PCB
5. Boiler control thermostat
6. Limit thermostat (manual reset)
7. Boiler ON/OFF switch
8. Ignition lockout reset
9. Combined temperature and pressure gauge
Fig. 5
1
2
7
8
9
5
6
4
3

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Pegasus F3
5. STARTUP AND SHUTDOWN
5.01 Checks to be carried out at first startup
It is good practice to check the following at first startup: that the cut-off valves between the boiler and
heating system are open; that all is well pressurised and vented; that there are no gas or water leaks
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 procedure
Set the boiler control thermostat to the desired temperature (not below 50°C).
Open the gas cock upstream from the boiler.
Vent gas supply pipework.
Switch on boiler.
At this point the electronic control unit takes over and after a preset pause sends a command to the pilot
valve to open and triggers off the discharge to the spark electrodes, igniting the pilot burner.
The pilot burner flame, ionizing the detection electrode, sends a signal to the electronic control unit
which in turn sends a command to the main valve to open, igniting the main burner.
Theboiler now functions automatically,controlled by the boilercontrol thermostat and/or byany other
command/control devices.
Note 1: In the event of the electric power supply to the boiler being cut off, the burners shut down
and light up again automatically when the power returns.
Note 2: If after having closely following the startup procedure the burners fail to light and the reset
button warning light is lit, it means that the board has lockout and you should wait about 10
seconds before pressing the reset button.
After resetting, the board repeats the startup cycle.
If the burners still fail to light after the second attempt, read paragraph 9, “Fault finding”.
5.03 Temporary shutdown
To turn the boiler off temporarily, simply switch off the power supply to the appliance. The electrical
components will be without power and the main and pilot burners will remain off.
5.04 Long-term boiler shutdown
Turn off inlet gas cock to the boiler and switch off the power supply.
Caution: If the boiler remains unused for long periods during the winter, in order to avoid frost
damages you should pour a suitable anti-freeze into the system or drain it completely.

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Pegasus F3
5
4897
6
2
13
Key:
1. Inlet pressure test point
2. Burner pressure test point
3. Gas pressure switch
4. Pilot-safety gas valve
electrical terminal box
Fig. 6
5.05 Inspections and controls after startup
At first startup:
- Make sure the gas supply is perfectly leakproof.
- Make sure the pilot light is adequate and well adjusted.
- Test boiler ignition by starting it and turning it off using the control thermostat.
- Check that no flue products escapes from the boiler draft diverter indicating that either the flue is
blocked or the draft is insufficient.
- Check the efficiency of the flue while the boiler is working.
- Check that there are no leaks from the points where the boiler/flue connects to the boiler and the
flue.
- Check that gas consumption, measured by the gas meter, matches the figure indicated in the
technical data table.
- Check that the water is circulating properly between the boiler and heating units.
- Make sure that when the pilot flame is extinguished, the safety devices are activated, shutting off
the main gas burners.
6. REGULATING
6.01 Adjusting the pressure at the burner
As described above, the boiler is set up to operate on natural gas (G20); 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.
Adjust the supply pressure at the main burners by turning the adjusting screw 9 located under the
governor protection cap (fig. 6). To increase the pressure, turn the screw clockwise; to reduce the
pressure, turn it anticlockwise. For finer tuning, turn the main gas valve screw, using a 12-mm hex
wrench (fig. 7a).
The pilot light requires no adjustment.
Caution: Pressure measured at pressure test points 1 and 2 (fig. 6) is displayed 30 seconds or more
after performing the adjustment.
5. Main gas valve electrical terminal box
6. Pilot burner supply pipe
7. Gas governor
8. Protective cap
9. Gas pressure regulating screw

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6.02 Regulating the flow rate, pre-ignition and speed of opening of the main gas valve
Fig. 7a
Adjusting flow rate
· After unscrewing the screws, remove the top cover.
· Use a 12-mm hex spanner.
· Turn clockwise to reduce the flow rate or anticlockwise to
increase it.
· Replace the cover and the screws.
Adjusting pre-ignition
· After unscrewing the screws, remove the top cover.
· Turn the central regulating screw with a screwdriver.
· Turn clockwise to reduce and anticlockwise to increase it.
· Replace the cover and the screws.
Adjusting opening speed
· After removing the screws, remove the top cover.
· Turn the side regulating screw with a screwdriver.
· Turn clockwise to reduce the flow rate and anticlockwise to
increase it.
· Replace the cover and the screws.
Fig. 7b
Fig. 7c

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Pegasus F3
6.03 Pilot burner unit (fig. 8a - 8b)
Key
1. Combustion chamber cover plate
2. Inspection window
3. Pilot burner
4. Ignitionelectrode
5. Flame rectification probe
6. Pilot injector
7. High tension lead
8. Pilot gas supply
3
3 ÷4 mm
5
8
4
2
3
4
5
6
7
8
Fig. 8a
Fig. 8b
1
7. FUEL CONVERSION (from natural to L.P.G.)
The following conversion operations are to be performed by qualified personnel only. We recommend
you contact our local Customer Technical Support Centres.
Whenever you have to convert the boiler from natural gas to LPG, proceed as follows:
· Completely dismantle the main burner.
· Replace the injectors.
· Reassemble the main burner.
· Re-set gas governor.

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Pegasus F3
7.01 Dismantling the main burner
· Turn off the gas cock and switch off the power supply to the boiler.
· Dis-connect and isolate gas governor.
· Unscrew the two screws that fasten the main burner to the boiler.
· Disconnect the cables from the electrodes.
· Disconnect the pilot burner gas supply pipe.
· Remove main burners.
7.02 Replacing the injectors
Remove the main burners from the manifold. Remove the existing main injectors and replace with
those required for LPG (see table 3), taking care not to damage the seal gaskets. Remove the pilot burner
injector, loosening the joint to the gas supply pipe, and replace with the required injector.
Note: The LPG conversion kit may be ordered from our commercial boiler sales department.
7.03 Reassembling the main burner
Repeat the steps described in paragraph 7.01 in reverse order, being particularly careful to position and
secure the various components accurately.
7.04 Setting the pressure stabiliser
Adjust the pressure stabiliser upstream from the gas valve as follows (fig. 9): Unscrew the protection
cap 1 and the regulating screw 2. Insert the spacer 3 (provided on request). Screw the regulating screw
2 all the way in so that the spacer is held tight.
Replace the protective cap.
Important:After having completed the various steps involved in converting the boiler from natural gas
to LPG, or vice versa, make sure there are no gas leaks.
Key
1. Protective cap
2. Regulating screw
3. Spacer (provided on request) L.P.G.
4. Spring
5. Gas governor
Fig. 9

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Pegasus F3
8. MAINTENANCE AND CLEANING
The following operations are to be performed by qualified personnel only.
8.01 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 flueways, burner and flue are clean.
That the water in the system is at the correct pressure – or correct level in the case of an open system.
That all control and safety devices operate correctly.
That the probe and spark electrode are free of carbon deposits.
That the pilot flame correctly aligns with the probe.
That circulation pumps are are free running.
That there are no gas leaks.
That the gas flow rate and pressure are correct.
That the pressure in the expansion vessel is as indicated in table 3 (page 5).
8.02 Cleaning the boiler and the flue
To clean the boiler and the flue, remove the burner bars from the combustion chamber.
For access to the cast-iron exchanger, proceed as follows (fig. 10): Remove the cover of the casing
secured by slot pins; pull out the insulation covering the draft diverter, remove the smoke-box
inspection cover 2 and its insulation, secured with self-threading screws 1.
Now you may clean all the flue gases passages in the boiler using a pipe brush 3. Remember you should
check and if necessary clean the flue and its connection to the boiler.
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
correctposition. Then check thesealalong the gas andflue circuits,
functioning of the control and safety devices and gas pressure and
rate of flow.
Key
1Securing screws
2Inspection cover with insulation
3Flue cleaning brush
4Flue gas sampling point
Fig. 10
1
2
4
3

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Pegasus F3
9. FAULT FINDING
Fault Cause and Corrective Action
After a few startup attempts,
The pilot burner is clogged or dirty.
the electronic control unit fails to
ignite the boiler
Check that the gas flow to the boiler is normal and that
air in the pipes has been removed.
Check that the electrodes are in their correct position
and free from scales (see fig. 8b).
Make sure the boiler is connected to the power supply
and is well earthed.
Check that the pilot gas valve is powered up.
Check the connections to the detection and spark
electrodes.
At startup, there is no electric Check that the electrodes are in their right
discharge between the electrodes position and free from scales.
Regulating thermostat is set too low.
Check the power supply.
Check the connections to the electronic control unit.
Make sure the NEUTRAL-PHASE connections have
not been reversed and the earth connection is effec-
tive.
Check incoming gas pressure and make sure the gas
pressure switch is open.
Reset the flue gas thermostat.
Reset the safety thermostat.
No pilot ignition No or little gas
Air is held in the pipes
.
Vent it as described in the chapter on startup.
Pilot injector is clogged or dirty.
Clean the injector with compressed air.
Poor pilot flame Pilot injector is dirty .
Poor main burner flame:
Gas valve filter is dirty.
too high, too low or too yellow
Check that gas pressure at the burner is normal (see
table 3 paragraph 2.02).
Injectors are dirty.
Smell of unburnt gas Check the boiler is clean.
Check that draft is sufficient.
Check that gas consumption is not excessive.

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Pegasus F3
No rise in temperature Make sure the regulating thermostat works.
while the boiler is working Check that gas consumption is not below specifica-
tions.
Check that the boiler is perfectly clean.
Check that the boiler rating is in proportion to the
system.
System water temperature is Check the functioning of the regulating
too high or too low thermostat.
Check the pump is not blocked.
Make sure the pump characteristics are in proportion
to the size of the system.
Flare-ups at the burner Check that the gas pressure is sufficient
Delayed ignition and that the boiler body is not dirty.
Regulating thermostat restarts Replace the thermostat .
with too high a temperature
difference
Boiler forms condensate
Check that the boiler is not running at too low a
temperature.
Check that gas consumption is normal. Make sure the
burner flame is well adjusted.
Boiler becomes dirty quickly Check that the burner flame is adjusted properly and
that gas consumption is in proportion to the boiler
power.
Boiler shuts off Gas pressure switch tripped (5 mbar).
for no apparent reason
Safety thermostat tripped after safe operating tempera-
ture has been exceeded.
Pilot injector is blocked or dirty.
Electrodes are dirty or badly positioned (see fig. 8b).
Remember: To avoid unnecessary expense, before contacting Service Department, make sure that
any boiler failure is not due to the absence of electric power or gas supply.

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