PEGASUS F2 - Ferroli€¦ · PEGASUS F2 Models 51 - 68 - 85 - 102 Appr. nr. A 9503 A - 0085 AQ 0765 cod. 3543463/0 - 01/01. Pegasus F2 2 Contents 1.1. ... HONEYWELL 82 32 18 17 16

INSTALLATION ANDINSTALLATION ANDINSTALLATION ANDINSTALLATION ANDINSTALLATION ANDMAINTENANCE INSTRUCTIONSMAINTENANCE INSTRUCTIONSMAINTENANCE INSTRUCTIONSMAINTENANCE INSTRUCTIONSMAINTENANCE INSTRUCTIONS

GAS-FIRED CAST-IRON BOILERSGAS-FIRED CAST-IRON BOILERSGAS-FIRED CAST-IRON BOILERSGAS-FIRED CAST-IRON BOILERSGAS-FIRED CAST-IRON BOILERSWITH ELECTRONIC IGNITIONWITH ELECTRONIC IGNITIONWITH ELECTRONIC IGNITIONWITH ELECTRONIC IGNITIONWITH ELECTRONIC IGNITION

AND FLAME RECTIFICATION MONITORINGAND FLAME RECTIFICATION MONITORINGAND FLAME RECTIFICATION MONITORINGAND FLAME RECTIFICATION MONITORINGAND FLAME RECTIFICATION MONITORING

PEGASUS F2PEGASUS F2PEGASUS F2PEGASUS F2PEGASUS F2

Models 51 - 68 - 85 - 102Models 51 - 68 - 85 - 102Models 51 - 68 - 85 - 102Models 51 - 68 - 85 - 102Models 51 - 68 - 85 - 102

App

r. n

r. A

950

3 A

- 0

085

AQ

076

5co

d. 3

5434

63/0

- 0

1/01

Pegasus F2Pegasus F2Pegasus F2Pegasus F2Pegasus F2

2

ContentsContentsContentsContentsContents

1.1.1.1.1. General technical data .............................................................................................................. 32.2.2.2.2. Dimensions and technical data ................................................................................................. 33.3.3.3.3. Boiler installation ...................................................................................................................... 74.4.4.4.4. Wiring and connection diagrams............................................................................................... 85.5.5.5.5. Startup and shutdown ............................................................................................................. 136.6.6.6.6. Regulating ............................................................................................................................... 157.7.7.7.7. Fuel conversion (from natural to l.p.g. Gas) ............................................................................. 198.8.8.8.8. Maintenance and cleaning ...................................................................................................... 209.9.9.9.9. Fault finding ............................................................................................................................ 21

3


1. GENERAL TECHNICAL DATA1. GENERAL TECHNICAL DATA1. GENERAL TECHNICAL DATA1. GENERAL TECHNICAL DATA1. GENERAL TECHNICAL DATA

1.011.011.011.011.01 IntroductionIntroductionIntroductionIntroductionIntroduction

The Pegasus F2Pegasus F2Pegasus F2Pegasus F2Pegasus F2, with CE approval, is designed for use with natural gas (G20) or LPG (G31) for indirectcentral heating and hot water.

1.021.021.021.021.02 Installation requirementsInstallation requirementsInstallation requirementsInstallation requirementsInstallation 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 LocalAuthorities, gas supplier and Insurance Companies.

2. DIMENSIONS AND TECHNICAL DATA2. DIMENSIONS AND TECHNICAL DATA2. DIMENSIONS AND TECHNICAL DATA2. DIMENSIONS AND TECHNICAL DATA2. DIMENSIONS AND TECHNICAL DATA

2.012.012.012.012.01 Dimensional data (see fig. 1 and table 2)Dimensional data (see fig. 1 and table 2)Dimensional data (see fig. 1 and table 2)Dimensional data (see fig. 1 and table 2)Dimensional data (see fig. 1 and table 2)

Fig. 1

a1a1a1a1a1 - Return 1" 1/2a2a2a2a2a2 - flow 1" 1/2a3a3a3a3a3 - Gas inlet 3/4"

a2

C

E

D

a1

a3

222

672

762

900

B

A

1000


4

2.022.022.022.022.02 Technical dataTechnical dataTechnical dataTechnical dataTechnical data

The standard cast-iron PEGASUS F2PEGASUS F2PEGASUS F2PEGASUS F2PEGASUS F2 boiler is set to operate on natural gas (G20).

The boiler is designed to operate with a flow temperature of 82°C and a maximum ∆t of 20°C.

Tabl

e 3

MODELGAS FLOW RATEPILOT

INJECTORSØ mm

0,24

0,24

0,24

0,24

G.P.L. G31

No. OF MAINBURNERS

3

4

5

6

GAS SUPPLYPRESSURE

(mbars)

GAS PRESS. ATBURNER MANIFOLD

(mbars)

Pegasus F2 51

Pegasus F2 68

Pegasus F2 85

Pegasus F2 102

MODELDIMENSIONS CONNECTIONS

Tabl

e 2

Amm

550

640

720

800

Bmm

96,5

96,5

106,5

106,5

CØ mm

180

180

200

200

Dmm

43

46

44

42

Emm

35

38

36

34

RETURNa1 Ø

1 1/2"

1 1/2"

1 1/2"

1 1/2"

WEIGHTINCLUDINGPACKAGE

Kg.

Pegasus F2 51

Pegasus F2 68

Pegasus F2 85

Pegasus F2 102

1 1/2"

1 1/2"

1 1/2"

1 1/2"

FLOWa2 Ø

GASa3 Ø

3/4"

3/4"

3/4"

3/4"

MAXOPERATINGPRESSURE

(bars)

4

4

4

4

WATERCONTENT

(liter)

22

26

30

34

MODEL

Tabl

e 1 Pegasus F2 51

Pegasus F2 68

Pegasus F2 85

Pegasus F2 102

NUMBER OFSECTIONS

4

5

6

7

HEAT INPUT(GROSS)

kW

62,2

83

103,8

124,3

HEAT INPUT(NETT)

kW

56

74,8

93,5

112

HEATOUTPUT

kW

51

68

85

102

260

300

350

400

15 to 23

15 to 23

15 to 23

15 to 23

Nat. G20

37

37

37

37

LPG G31

13,3

13,3

13,3

13,3

Nat. G20

36

36

36

36

LPG G31

5,9

7,9

9,9

11,8

Nat. G20m3/h

4,34

5,79

7,24

8,68

LPG G31kg/h

0,4

0,4

0,4

0,4

Nat. G20

PRINCIPALESINJECTORS

Ø mm

2,15

2,15

2,15

2,15

G.P.L. G31

3,5

3,5

3,5

3,5

Nat. G20

5


1

8 97

2 4 6 3

5

Control panel Control panel Control panel Control panel Control panel

Fig. 2b

Front view of the boiler without front casing Front view of the boiler without front casing Front view of the boiler without front casing Front view of the boiler without front casing Front view of the boiler without front casing

Fig. 2a

KeyKeyKeyKeyKey

11111 Temperature-pressure gauge22222 Boiler control thermostat33333 Ignition lockout re-set botton44444 Boiler on/off switch55555 Flue gas safety thermostat66666 Limit thermostat reset botton77777 Ignition PCB88888 Electronic panel (not available UK)

1 2

4

13

14

10

12

9

816

1115

6 3

752.032.032.032.032.03 Main componentsMain componentsMain componentsMain componentsMain components

99999 Control panel1010101010 Gas valve1111111111 Pilot burner assembly1212121212 Gas burner manifold1313131313 Gas pressure test point1414141414 Automatic air vent1515151515 Drain cock1616161616 Flue gas sampling point


6

Fig. 3

2.042.042.042.042.04 Characteristic pressure drop curveCharacteristic pressure drop curveCharacteristic pressure drop curveCharacteristic pressure drop curveCharacteristic pressure drop curve

Water pressure drop in all models is shown in fig.3. The following diagram shows the pressure dropin the boiler as a function of the water flow rate.

1 2 3 4 5 6 7 8 9 10

10

20

30

40

50

60

70

8090

4 EL

.

100

5 EL

.6

EL.

7 EL

.

∆P mbar

Flow rate

200

2.052.052.052.052.05 Safe discharge of combustion productsSafe discharge of combustion productsSafe discharge of combustion productsSafe discharge of combustion productsSafe discharge of combustion products

The boiler comes with a FLUE GAS SAFETY THERMOSTAT, which provides a high level of safety andcontrol over the discharge of combustion products. This thermostat cuts off the supply of gas to theburner in the event of a faulty flue draft.

If the FLUE GAS SAFETY THERMOSTAT has been activated, you should unscrew the protection cover(part no. 5 in fig. 2a and 2b) and manually“reset” the thermostat. After that, the boilerwill return to normal operation.

If the FLUE GAS SAFETY THERMOSTATneeds to be replaced, use originalmanufacturer’s parts only and make surethe electric connections and positioning ofthe bulb (see fig. 4) are correct; NEVERUNDER ANY CIRCUMSTANCES LEAVETHE FLUE GAS SAFETY THERMOSTATDISCONNECTED FROM THE ELECTRICCIRCUIT.In case of frequent tripping of the thermo-static switch, contact qualified personnelonly.During cleaning of the draft diverter, becareful not to damage the thermostat phial. Flue gas safety

thermostat phial

Boiler rear viewBoiler rear viewBoiler rear viewBoiler rear viewBoiler rear view

Fig. 4

7


3. BOILER INSTALLATION3. BOILER INSTALLATION3. BOILER INSTALLATION3. BOILER INSTALLATION3. BOILER INSTALLATION(To be performed by qualified personnel only)

3.013.013.013.013.01 General warningsGeneral warningsGeneral warningsGeneral warningsGeneral warnings

The boiler should be installed according to current regulations (see para 1.02).

We suggest fitting isolating valves between the boiler and the heating system to isolate the boiler fromthe system if necessary.

The rise in temperature of the heating water (the difference between the water flow and returntemperatures) should not exceed 20°C. This is so as to prevent possible damage caused bycondensation forming in the boiler.

Combustion products should be discharged through a flue with a cross section in accordance withcurrent standards and not less than the boiler flue outlet connection.

Connect the gas to the boiler in accordance with current regulations. The diameter of the boiler gasinlet gas pipe does not dictate the choice of diameter for the pipe between the boiler and the gas metershould be calculated based upon its length and pressure drop.

3.023.023.023.023.02 Boiler water characteristicsBoiler water characteristicsBoiler water characteristicsBoiler water characteristicsBoiler water characteristics

When the water supply has a hardness of more than 25 - 30 Fr., it should be treated before enteringthe heating system to prevent both scaling (caused by hard water) and corrosion (caused by aggressivewater) in the boiler. Please remember that because of their low thermal conductivity, even small scalesjust 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:You must treat the water used for the heating system in the following cases:You must treat the water used for the heating system in the following cases:You must treat the water used for the heating system in the following cases:You must treat the water used for the heating system in the following cases:

A) Very large systems (with large volumes of water).A) Very large systems (with large volumes of water).A) Very large systems (with large volumes of water).A) Very large systems (with large volumes of water).A) Very large systems (with large volumes of water).B) Systems where partial or complete draining - and water refilling - are frequent.B) Systems where partial or complete draining - and water refilling - are frequent.B) Systems where partial or complete draining - and water refilling - are frequent.B) Systems where partial or complete draining - and water refilling - are frequent.B) Systems where partial or complete draining - and water refilling - are frequent.


8

4. WIRING AND CONNECTION DIAGRAMS4. WIRING AND CONNECTION DIAGRAMS4. WIRING AND CONNECTION DIAGRAMS4. WIRING AND CONNECTION DIAGRAMS4. WIRING AND CONNECTION DIAGRAMS

4.014.014.014.014.01 Electrical connectionsElectrical connectionsElectrical connectionsElectrical connectionsElectrical connections

- 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 standardterminal block or outlet with 2A max. fuses connected between the boiler and the power support.Remember that the boiler should always be provided with good earthing.

IMPORTANT:IMPORTANT:IMPORTANT:IMPORTANT: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 byfailure to earth the boiler correctly.

General wiring diagram for mod. 51-68-85General wiring diagram for mod. 51-68-85General wiring diagram for mod. 51-68-85General wiring diagram for mod. 51-68-85General wiring diagram for mod. 51-68-85

Fig. 5a

Note:Note:Note:Note:Note:• Dotted lines indicate connections to be performed during installation.• Terminals L1, N1, 6 are reserved for connecting an electronic compensator (not available in UK)

17

22

72

20

83

117

32

24

8225

98

L

N

230V50Hz

X3

X6

X4X5

14616

9253 7 131

3

1

4

2

129

1

12

9

C

4

18

17

7

5

19

2

1

3

4 2

3 1

6

8

N1

L1

114

116

160

63

118

2

92

15

13

14

11

10

S 4561 BHONEYWELL

21

16

49

4

169

2 1

3

KeyKeyKeyKeyKey

2424242424 Spark electrode2525252525 Pilot burner3232323232 Pump (not supplied)4949494949 Limit thermostat (manual reset)6363636363 Boiler control thermostat7272727272 Room thermostat

8282828282 Ionization probe8383838383 Ignition PCB9292929292 Flue gas thermostat9898989898 Boiler on/off switch

114114114114114 Water flow pressure switch(not supplied)

116116116116116 Gas pressure switch117117117117117 Main gas valve118118118118118 Pilot light gas valve129129129129129 Ignition lockout re-set botton160160160160160 Auxiliary contact169169169169169 Suppression filter

9


Electrical connections diagram for mod. 51-68-85Electrical connections diagram for mod. 51-68-85Electrical connections diagram for mod. 51-68-85Electrical connections diagram for mod. 51-68-85Electrical connections diagram for mod. 51-68-85

Fig. 5b

Note:Note:Note:Note:Note:• Dotted lines indicate connections to be performed during installation.• Terminals L1, N1, 6 are reserved for connecting an electronic compensator (not available in UK)

49

83

2582

160114 117118

129

32

3 51 42 20191817161514131211 22219876 10

L N

2

2

4

L N

3 9 17142 5 6 71

1

N1

230V50Hz 72

L1

C

X4

X5

X6

N

X3

1

L

S 4561 BHONEYWELL

3

13 16

63

24

92

116

2423

3

1

2

169

4

1

4

2

3

98

KeyKeyKeyKeyKey

2424242424 Spark electrode2525252525 Pilot burner3232323232 Pump (not supplied)4949494949 Limit thermostat (manual reset)6363636363 Boiler control thermostat7272727272 Room thermostat

8282828282 Ionization probe8383838383 Ignition PCB9292929292 Flue gas thermostat9898989898 Boiler on/off switch

114114114114114 Water flow pressure switch(not supplied)

116116116116116 Gas pressure switch117117117117117 Main gas valve118118118118118 Pilot light gas valve129129129129129 Ignition lockout re-set botton160160160160160 Auxiliary contact169169169169169 Suppression filter


10

12

11

10

9

C

7 8

13

114

116

160

24X6

X5

9253 7 13

3

1

4

2

129

1632

92

15

14

49

2

3

4 2

6

3 1L

1

230V50Hz

25

20

X3

X414

83

61617

1

1922

118

21

117

S 4561 BHONEYWELL

82

32

18

17

16

4

5 N1

L1

98

4

169

2 1

3

N

General wiring diagram for mod. 102General wiring diagram for mod. 102General wiring diagram for mod. 102General wiring diagram for mod. 102General wiring diagram for mod. 102

KeyKeyKeyKeyKey

2424242424 Spark electrode2525252525 Pilot burner3232323232 Pump (not supplied)4949494949 Limit thermostat (manual reset)6363636363 Boiler control thermostat8282828282 Ionization probe8383838383 Ignition PCB9292929292 Flue gas thermostat

9898989898 Boiler on/off switch114114114114114 Water flow pressure switch (not supplied)116116116116116 Gas pressure switch117117117117117 Main gas valve118118118118118 Pilot light gas valve129129129129129 Ignition lockout re-set botton160160160160160 Auxiliary contact169169169169169 Suppression filter

Fig. 5c

Note:Note:Note:Note:Note: Dotted lines indicate connections to be performed during installation.Terminals L1, N1, 6 are reserved for connecting an electronic compensator (not available inUK)

11


Electrical connections diagram for mod. 102Electrical connections diagram for mod. 102Electrical connections diagram for mod. 102Electrical connections diagram for mod. 102Electrical connections diagram for mod. 102

S 4561 BHONEYWELL

117118

L N N L

3249

3 51 42 20191817161514131211 22219876 10

116 160114

N1L1

L N230V50Hz

2

4

1

3

129

92

X4

X5

X6

X3

2582

24

1714 1613

3

2 4

1

2 1

C63

3 92 5 6 71

83

169

1

4

2

3

98

Fig. 5dKeyKeyKeyKeyKey

2424242424 Spark electrode2525252525 Pilot burner3232323232 Pump (not supplied)4949494949 Limit thermostat (manual reset)6363636363 Boiler control thermostat8282828282 Ionization probe8383838383 Ignition PCB9292929292 Flue gas thermostat

9898989898 Boiler on/off switch114114114114114 Water pressure switch (not supplied)116116116116116 Gas pressure switch117117117117117 Main gas valve118118118118118 Pilot light gas valve129129129129129 Ignition lockout reset botton160160160160160 Auxiliary contact

Note:Note:Note:Note:Note: Dotted lines indicate connections to be performed during installation.Terminals L1, N1, 6 are reserved for connecting an electronic compensator (not avbailable inUK)


12

4.034.034.034.034.03 Exploded view of the control panel (fig. 6)Exploded view of the control panel (fig. 6)Exploded view of the control panel (fig. 6)Exploded view of the control panel (fig. 6)Exploded view of the control panel (fig. 6)

4.02 Access to the control panel internal components4.02 Access to the control panel internal components4.02 Access to the control panel internal components4.02 Access to the control panel internal components4.02 Access to the control panel internal components

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:Caution:Caution:Caution:Caution: Handle the flame control electronic board (part 4 in fig. 6) and its connections withparticular care.

KeyKeyKeyKeyKey

1.1.1.1.1. Control panel2.2.2.2.2. Wiring harness protection plate3.3.3.3.3. Terminal block4.4.4.4.4. Ignition PCB5.5.5.5.5. Boiler control thermostat

6.6.6.6.6. Limit thermostat (manual reset)7.7.7.7.7. Flue gas thermostat8.8.8.8.8. Boiler on/off switch9.9.9.9.9. Ignition lockout reset10.10.10.10.10. Combined temperature and pressure gauge

Fig. 6

11111

22222

66666

99999

88888

1010101010

55555

77777

44444

33333

13


5. STARTUP AND SHUTDOWN5. STARTUP AND SHUTDOWN5. STARTUP AND SHUTDOWN5. STARTUP AND SHUTDOWN5. STARTUP AND SHUTDOWN

5.015.015.015.015.01 Checks to be carried out at first startupChecks to be carried out at first startupChecks to be carried out at first startupChecks to be carried out at first startupChecks to be carried out at first startup

It is good practice to check the following at first startup: that the cutoff valves between the boiler andheating system are open; that all is well pressurized and vented; that there are no gas or water leaksfrom the water system or boiler; that the electrical connections are correct and the earthing cableconnected to a good earthing system; that there are no inflammable liquids or materials in theimmediate vicinity of the boiler and that the flue is not blocked.

5.025.025.025.025.02 Startup procedureStartup procedureStartup procedureStartup procedureStartup procedure

- Set the boiler control thermostat knob 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 pilotvalve 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 unitwhich in turn sends a command to the main valve to open, igniting the main burner.The boiler now functions automatically, controlled by the boiler control thermostat and/or by any othercommand/control devices (room thermostat, electronic thermostat board, etc.).

Note:Note:Note:Note:Note: If after having closely followed the startup procedure the burners fail to light and the reset buttonwarning light on the electronic control unit is lit, it means that the board has locked out and youshould 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”.In the event of the electric power supply to the boiler being cut off, the burners shut down andlight up again automatically when the power returns.

5.035.035.035.035.03 Temporary shutdownTemporary shutdownTemporary shutdownTemporary shutdownTemporary shutdown

To turn the boiler off temporarily, simply switch off the power supply to the boiler. The electricalcomponents will be without power and the main and pilot burners will remain off.

5.045.045.045.045.04 Long-term boiler shutdownLong-term boiler shutdownLong-term boiler shutdownLong-term boiler shutdownLong-term boiler shutdown

Turn off inlet gas cock to the boiler and switch off the power supply.

Caution:Caution:Caution:Caution:Caution: If the boiler remains unused for long periods during the winter, in order to avoid frostdamages you should pour a suitable anti-freeze into the system or drain it completely.


14

5.05 Inspections and controls after startup5.05 Inspections and controls after startup5.05 Inspections and controls after startup5.05 Inspections and controls after startup5.05 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.

15


Key:Key:Key:Key:Key:

1.1.1.1.1. Inlet pressure test point2.2.2.2.2. Outlet pressure test point3.3.3.3.3. Screw block stabilizer4.4.4.4.4. Pilot coil electric connections5.5.5.5.5. Main burner coil electric connections6.6.6.6.6. Pilot burner supply7.7.7.7.7. Main burner gas pressure adjustment screw

Fig. 7

6. REGULATING6. REGULATING6. REGULATING6. REGULATING6. REGULATING

As described above, the boiler is set up to operate on natural gas (G20); gas pressure has been testedand calibrated by the manufacturer.However, due to possible differences in pressure in the gas supply system, at first startup you shouldcheck and if necessary adjust the pressure at the injectors to match the pressure level shown in table3 (paragraph 2.02) of the technical data.

6.02 Gas pressure adjustment with the “Honeywell VR 4601 CB” valve in models 51-68-856.02 Gas pressure adjustment with the “Honeywell VR 4601 CB” valve in models 51-68-856.02 Gas pressure adjustment with the “Honeywell VR 4601 CB” valve in models 51-68-856.02 Gas pressure adjustment with the “Honeywell VR 4601 CB” valve in models 51-68-856.02 Gas pressure adjustment with the “Honeywell VR 4601 CB” valve in models 51-68-85

Adjust the supply pressure at the main burners by turning the stabilizer screw 7 (fig. 7).To increase the pressure, turn the screw clockwise. To decrease the pressure, turn the screwanticlockwise.The pilot light requires no adjustment.

Caution:Caution:Caution:Caution:Caution: Pressure measured at pressure test points 1 and 2 (fig. 7) is displayed 30 seconds or moreafter making the adjustment.

6

3

7 2

1

5

4


16

6.036.036.036.036.03 Gas pressure adjustment with the “DUNGS MBDLE 407 BO1” valve in model 102Gas pressure adjustment with the “DUNGS MBDLE 407 BO1” valve in model 102Gas pressure adjustment with the “DUNGS MBDLE 407 BO1” valve in model 102Gas pressure adjustment with the “DUNGS MBDLE 407 BO1” valve in model 102Gas pressure adjustment with the “DUNGS MBDLE 407 BO1” valve in model 102

Pe

Pa

13

4

5

6

8

7 2

9

Fig. 8

Key:Key:Key:Key:Key:

1.1.1.1.1. Inlet gas pressure test point(Burner pressure is measured at test point on burner manifold)

2.2.2.2.2. Pilot burner supply3.3.3.3.3. Integral gas pressure switch4.4.4.4.4. Gas pressure switch connector (grey)5.5.5.5.5. V1-V2 gas valve power connector (black)6.6.6.6.6. Gas governor7.7.7.7.7. Gas flow rate regulator (valve V2)8.8.8.8.8. Slow startup regulator (under the cover)9.9.9.9.9. Cover protecting the incoming gas filter.

17


Gas pressure adjustment:Gas pressure adjustment:Gas pressure adjustment:Gas pressure adjustment:Gas pressure adjustment:

- Move the protective cover by turning it on its hinges.- Using a small screwdriver (no. 3), turn the regulating screw toset the required pressure.

Note:Note:Note:Note:Note: The pilot light requires no adjustments.

Fig. 8a

Slow startup adjustmentSlow startup adjustmentSlow startup adjustmentSlow startup adjustmentSlow startup adjustment

- Unscrew the black plastic cap- Using the cap as a tool turn the pin under it to the desiredsetting.- Screw the plastic cap back.

Fig. 8c

Main gas flow rate adjustmentMain gas flow rate adjustmentMain gas flow rate adjustmentMain gas flow rate adjustmentMain gas flow rate adjustment (valve V2)

- Loosen the securing screw using a screwdriver.- Turn the knob to the required setting, then re-tighten thesecuring screw.

Note:Note:Note:Note:Note: Pressure measured at pressure test points is displayed 30seconds or more after performing the adjustment.

Fig. 8b


18

6.046.046.046.046.04 Pilot burner unit (fig. 9)Pilot burner unit (fig. 9)Pilot burner unit (fig. 9)Pilot burner unit (fig. 9)Pilot burner unit (fig. 9)

KeyKeyKeyKeyKey

11111 Combustion chamber cover plate22222 Inspection window33333 Pilot burner44444 Ignition electrode55555 Flame rectification probe66666 Pilot injector77777 Ht lead88888 Pilot gas supply

3

3 ÷ 4 mm

5

8

4

Fig. 9

19


Fig. 10

7. FUEL CONVERSION (from natural to L.P.G. Gas)7. FUEL CONVERSION (from natural to L.P.G. Gas)7. FUEL CONVERSION (from natural to L.P.G. Gas)7. FUEL CONVERSION (from natural to L.P.G. Gas)7. FUEL CONVERSION (from natural to L.P.G. Gas)

In order to carry out such operation it must replace the main nozzles and that pilot, proceeding in thefollowing way:

- Turn off the gas and switch off the power supply to the boiler.- Remove the main gas burners.- Disassemble the pilot burner (fig. 8).- Remove the main burners from manifold.- Replace the main and pilot injectors taking care not to spoil the main injector sealing gaskets. If they

have been damaged, replace them.- Re-assemble with care.- Carefully screw in fully the pressure regulating screw 7 (fig. 7) on the “Honeywell VR 4601 CB” gas

valve in models 51-68-85 and the screws (fig. 8a and 8b) on the “DUNGS MBDLE 407 BO1” valvein model 102.

- Check that the boiler functions correctly and that there are no gas leaks.

Moreover for the version with "Honeywell VR 4601 CB" gas valve (for models 51-68-85) should bemounted on the body valve the appropriate calibrated adapter of slow ignition (supplied on request),operating in the following way:- remove from the body valve gas the plastic protection cover “M”“M”“M”“M”“M” (fig. 10)- screw the adapter N to the body gas valve- replace the of protection cover “M”“M”“M”“M”“M” on the adapter.

REMEMBER:REMEMBER:REMEMBER:REMEMBER:REMEMBER: The L.P.G. injector kit may be obtained from our Commercial boiler sales department.


20

8. MAINTENANCE AND CLEANING8. MAINTENANCE AND CLEANING8. MAINTENANCE AND CLEANING8. MAINTENANCE AND CLEANING8. MAINTENANCE AND CLEANING

The following operations are to be performed by qualified personnel only.

8.018.018.018.018.01 Seasonal inspection of the boiler and flueSeasonal inspection of the boiler and flueSeasonal inspection of the boiler and flueSeasonal inspection of the boiler and flueSeasonal inspection of the boiler and flue

Before the beginning of winter you should perform a general inspection of the boiler, heating systemand 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 properly.That the probeand spark electrode are free of carbon deposits.That the pilot flame correctly aligns with the probe.That circulation pumps 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 (paragraph 2.02).

8.028.028.028.028.02 Cleaning the boiler and the flueCleaning the boiler and the flueCleaning the boiler and the flueCleaning the boiler and the flueCleaning 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. 11): Remove the cover of the casingsecured by slot pins; pull out the insulation covering the draft diverter, remove the smoke-boxinspection cover 2 and its insulation, secured with self-threading screws 1.Now you may clean all the smoke passages in the boiler using a pipe brush 3. Remember you shouldcheck and if necessary clean the flue and its connection to the boiler. Be careful not to damage the Fluegas safety thermostat phial or capillary.

ImportantImportantImportantImportantImportant - Do not clean the burners with chemicals or a steelbrush, as these might change the air-gas mixture outlet holes.When cleaning is complete, re-assemble carefully and in thecorrect position. Then check the seal along the gas and smokecircuits, functioning of the control and safety devices and gaspressure and rate of flow.

KeyKeyKeyKeyKey

11111 Securing screws22222 Inspection cover with insulation33333 Flue cleaning brush44444 Flue gas sampling point Fig. 11

11111

22222

4444433333

21


9. FAULT FINDING9. FAULT FINDING9. FAULT FINDING9. FAULT FINDING9. FAULT FINDING

FaultFaultFaultFaultFault Cause and Corrective ActionCause and Corrective ActionCause and Corrective ActionCause and Corrective ActionCause and Corrective Action

After a few startup attempts,After a few startup attempts,After a few startup attempts,After a few startup attempts,After a few startup attempts, The pilot burner is clogged or dirty.the electronic control unit fails tothe electronic control unit fails tothe electronic control unit fails tothe electronic control unit fails tothe electronic control unit fails toignite the boilerignite the boilerignite the boilerignite the boilerignite 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 andfree from scales (see fig. 9).Make sure the boiler is connected to the power supplyand is well earthed.Check that the pilot gas valve is powered up.Check the connections to the detection and spark elec-trodes.

At startup, there is no electricAt startup, there is no electricAt startup, there is no electricAt startup, there is no electricAt startup, there is no electric Check that the electrodes are in their rightdischarge between the electrodesdischarge between the electrodesdischarge between the electrodesdischarge between the electrodesdischarge 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 notbeen reversed and the earth connection is effective.Check incoming gas pressure and make sure the gaspressure switch is open.Reset the Flue gas safety thermostat.Reset the safety thermostat.

No pilot ignitionNo pilot ignitionNo pilot ignitionNo pilot ignitionNo pilot ignition No or little gasAir 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 flamePoor pilot flamePoor pilot flamePoor pilot flamePoor pilot flame Pilot injector is dirty.

Poor main burner flame:Poor main burner flame:Poor main burner flame:Poor main burner flame:Poor main burner flame: Gas valve filter is dirty.too high, too low or too yellowtoo high, too low or too yellowtoo high, too low or too yellowtoo high, too low or too yellowtoo 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 gasSmell of unburnt gasSmell of unburnt gasSmell of unburnt gasSmell of unburnt gas Check the boiler is clean.Check that draft is sufficient.Check that gas consumption is not excessive.

No rise in temperatureNo rise in temperatureNo rise in temperatureNo rise in temperatureNo rise in temperature Make sure the regulating thermostat works.while the boiler is workingwhile the boiler is workingwhile the boiler is workingwhile the boiler is workingwhile the boiler is working Check that gas consumption is not below specifications.

Remember:Remember:Remember:Remember:Remember: to avoid unnecessary expense, before contacting Service Department, make sure that anyboiler failure is not due to the absence of electric power or gas supply.

Check that the boiler is perfectly clean.Check that the boiler rating is in proportion to the system.

System water temperature isSystem water temperature isSystem water temperature isSystem water temperature isSystem water temperature is Check the functioning of the regulating thermostat.too high or too lowtoo high or too lowtoo high or too lowtoo high or too lowtoo high or too low Check the pump is not blocked.

Make sure the pump characteristics are in proportion tothe size of the system.

Flare-ups at the burnerFlare-ups at the burnerFlare-ups at the burnerFlare-ups at the burnerFlare-ups at the burner Check that the gas pressure is sufficientDelayed ignitionDelayed ignitionDelayed ignitionDelayed ignitionDelayed ignition and that the boiler body is not dirty.

Regulating thermostat restartsRegulating thermostat restartsRegulating thermostat restartsRegulating thermostat restartsRegulating thermostat restarts Check that the bulb is properly inserted.with too high a temperaturewith too high a temperaturewith too high a temperaturewith too high a temperaturewith too high a temperature Replace the thermostat.differencedifferencedifferencedifferencedifference

Boiler forms condensateBoiler forms condensateBoiler forms condensateBoiler forms condensateBoiler forms condensate Check that the boiler is not running at too low a tempera-ture.Check that gas consumption is normal. Make sure theburner flame is well adjusted.

Boiler becomes dirty quicklyBoiler becomes dirty quicklyBoiler becomes dirty quicklyBoiler becomes dirty quicklyBoiler becomes dirty quickly Check that the burner flame is adjusted properly and thatgas consumption is in proportion to the boiler power.

Boiler shuts offBoiler shuts offBoiler shuts offBoiler shuts offBoiler shuts off Flue gas safety thermostat tripped.for no apparent reasonfor no apparent reasonfor no apparent reasonfor no apparent reasonfor no apparent reason

Safety thermostat tripped after safe working temperaturehas been exceeded.

Lichfield Road, Branston Industrial Estate, Burton Upon Trent, Staffordshire DE14 3HDLichfield Road, Branston Industrial Estate, Burton Upon Trent, Staffordshire DE14 3HDLichfield Road, Branston Industrial Estate, Burton Upon Trent, Staffordshire DE14 3HDLichfield Road, Branston Industrial Estate, Burton Upon Trent, Staffordshire DE14 3HDLichfield Road, Branston Industrial Estate, Burton Upon Trent, Staffordshire DE14 3HDTel. 08707 282 885 - Fax 08707 282 886Tel. 08707 282 885 - Fax 08707 282 886Tel. 08707 282 885 - Fax 08707 282 886Tel. 08707 282 885 - Fax 08707 282 886Tel. 08707 282 885 - Fax 08707 282 886

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PEGASUS F2 - Ferroli€¦ · PEGASUS F2 Models 51 - 68 - 85 - 102 Appr. nr. A 9503 A - 0085 AQ 0765 cod. 3543463/0 - 01/01. Pegasus F2 2 Contents 1.1. ... HONEYWELL 82 32 18 17 16