Ferroli GN 3 Operating and maintenance manual

HIGH EFFICIENCY
CAST IRON BOILER
FOR LIQUID
and/or GAS FUELS
INSTALLATION
AND USE INSTRUCTIONS
GN 3

2
GN3

3
GN3
Thank you for having purchased a Ferroli boiler.
Your new GN3 has been built according to highly advanced technologies using strong and reliable materials.
Please follow our advice carefully and you will certainly get the best from your boiler. Ferroli quality also covers the
technical and functional features of the boiler which comply with the current provisions in merit.
Amongst the documents in the package supplied with this appliance, you will find:
* Instruction manual
* Certificate of Guarantee
Please comply with our instructions to ensure correct installation. The “CERTIFICATE OF GUARANTEE” should be
filled out withyour address and forwarded toFerroli for endorsement.
OurcompanyrunsanetworkofAfter-SalesServiceCenterstoensurepromptassistancethroughoutthehometerritory.
Thanking you once again for your preference, please remember that we are at your complete disposal for any further
information you may require.
Best regards. FERROLI
Industrie Riscaldamento S.p.A.
TABLE OF CONTENTS
Generalinformation....................................................................................................................................... page 3
Features ........................................................................................................................................................ page 4
Installation ..................................................................................................................................................... page 8
Assembling the boiler shell ............................................................................................................................ page 10
Assembling the casing .................................................................................................................................. page 17
Inspections.................................................................................................................................................... page 23
Adjustements ................................................................................................................................................ page 23
Servicing ....................................................................................................................................................... page 24

4
GN3
GENERAL INFORMATION
Description
Boiler GN3 is a new highly efficient heat generator. It
produces hot water for heating purposes and is able to
operate with either liquid and/or gas fuelled burners.
Theboilershellconsistsofcastironelementsassembled
with double steel cones and rods. The shape has been
speciallydesignedforoptimum fin distribution in order to
achievehighthermalefficiency with consequently excel-
lent enery savings.
Together with the dry chamber, the shape of the shell
enables this appliance to operate with delivery tempera-
turesofabout 60°Cwithouttheformationof condensate.
Boiler insulation consists of a thick layer of mineral wool
which reduces heat dispersion in the environment to the
minimum.
Packing (fig. 2)
BoilerGN3canbe supplied in two typesofpack:withthe
boiler shell assembled or in parts:
In the former case, 3 packs will be sent including:
1. Boiler body
2. Casing
3. Control panel
In the latter case, there will be 4 packs containing:
2. Casing
3. Control panel
4. Group of elements
5. Accessory kit
1. Boiler body
2. Casing 3. Control panel
4. Group of elements
5. Accessory kit
Fig. 1
Fig. 2
Burner inhibition warning light
Electronic plant (not supplied) Boiler thermometer
Burner switch and warning light
2nd burner stage operation
hour counter Safety thermostat
2nd burner stage adjuster thermostat
1st burner stage adjuster
thermostat
1st burner stage operation
hour counter

5
GN3
Technical brief (fig. 3)
FEATURES
Fig. 3
Key
1. Electronic plant (optional)
2. 1st burner stage operation hour counter
3. 2nd burner stage operation hour counter
4. Burner inhibition warning light
5. Boiler thermometer
6. Safety thermostat
7. Burner switch and warning light
8. 2nd burner stage adjuster thermostat
9. 1st burner stage adjuster thermostat
10. Pressure tap connection in combustion chamber
11. Porthole to inspect the flame
a1. Flow C.H. ND 80 - 3" Gas
a2. Return C.H. ND 80 - 3" Gas
250
11 10
6215789
3
4
A1
A2
855
88.5
690
A
437
1278
850
1180
193
Model
GN3 06
GN3 07
GN3 08
GN3 09
GN3 10
GN3 11
GN3 12
GN3 13
GN3 14
Model
GN3 06
GN3 07
GN3 08
GN3 09
GN3 10
GN3 11
GN3 12
GN3 13
GN3 14
116
130
144
158
172
186
197
211
225
Water
content
dm
3
6
7
8
9
10
11
12
13
14
Elements
n°
150
175
200
225
250
275
300
325
350
Min.
163
190
217
244
271
298
325
352
379
Min.
181.1
211.1
241.1
271.1
301.1
331.1
361.1
391.1
421.1
Min.
Heat and D.H.W.
(Output)
Heat and D.H.W.
(Net) (Gas+Oil)
Heat and D.H.W.
(Gross) (Gas)
4
4
4
4
4
4
4
4
4
Working
pressure
bar
780
890
1000
1110
1220
1330
1440
1550
1660
A
mm
113
120
145
170
195
220
245
270
297
Combustion
chamber
volume
dm
3
0.93
1.20
1.45
1.80
2.00
2.50
3.00
3.60
4.60
Pressure
combustion
chamber
∆p mbar
668
756
852
948
1044
1140
1236
1332
1428
Shell
weight
kg.
Water
load
loss
75
70
78
87
85
92
100
105
110
∆p 15 mbar
255.5
297.7
340
382.2
424.4
466.6
508.8
551.1
593.3
Max.
230
268
306
344
382
420
458
496
534
Max.
210
245
280
315
350
385
420
455
490
Max.

6
GN3
Boiler shell (fig. 4)
Fig. 4
26d 37401650 COMP.CYLINDER FOR COMB.CHAMBER - 9 elem.
26e 37401660 COMP.CYLINDER FOR COMB.CHAMBER -10 elem.
26f 37401660 COMP.CYLINDER FOR COMB.CHAMBER -11 elem.
26g 37401670 COMP.CYLINDER FOR COMB.CHAMBER -12 elem.
26h 37401670 COMP.CYLINDER FOR COMB.CHAMBER -13 elem.
26i 37401670 COMP.CYLINDER FOR COMB.CHAMBER -14 elem.
27 35315970 COMBUSTION CHAM.INSULATION
28 33202020 UPPER BOILER DOOR FN.
29 35315980 UPPER DOOR INSULATION
30 38008700 COMPLETE UPPER DOOR
31 38008820 COMPLETE BURNER DOOR
32 37511420 COMPLETE DOOR HANDLE
33 35002220 HANDLE 3P 110/B 6111090 M16
34 33202041 BOILER BURNER DOOR FN.
35 35315961 BURNER DOOR INSULATION D.586 THICKNESS 67
36 35316090 INNER DOOR INSUL. Ø 586 THICKNESS 6.4
37 32152530 FLANGE D.340 THICKNESS 12
38 35352910 CERAMIC FIBER SEAL D.340
39
40 34008850 PORTHOLE FLANGE 105x61 THICKNESS 8
41 33700860 SEAL 105x61 TH.2 FLANGE
42
43 33400280 VENT 1/6 WITH SMOOTH SEAL HOLDER
44 35352930 MICA DISK D.44 THICKNESS 0.5
45 34008940 PIN 12x50 UNI 1713
46
47 A0 38445240 WATER DISTRIBUTION PIPE FRONT SECTION
47 A1 38445230 WATER DISTRIBUTION PIPE FRONT SECTION
47 A2 38445220 WATER DISTRIBUTION PIPE FRONT SECTION
47 B3 38445250 WATER DISTRIBUTION PIPE REAR SECTION
47 B4 38445260 WATER DISTRIBUTION PIPE REAR SECTION
47 C2 34223560 WATER DISTRIBUTION PIPE MIDDLE SECTION
48 35100180 RUBBER SEAL ED 133 ID 90 TH.4
49 34008861 FLANGE C. 160x160 THICKNESS 16
54 34300320 SPRING CLIP
1 33004552 FRONT ELEMENT FN.
2 33004570 INTERMEDIATE ELEMENT FN.
2a 33004910 INTERMEDIATE ELEMENT (LOW HEIGHTS) FN.
3 33004580 INTERMEDIATE ELEMENT WITH LEGS FN.
4 33004560 REAR ELEMENT FN.
5 34205080 94.4 ED DOUBLE CONE 100.22 LG.45
6a 34403380 ROD M16x 780 THREAD 80/80 - 6 elem.
6b 34403390 ROD M16x 910 THREAD 80/80 - 7 elem.
6c 34403400 ROD M16x1040 THREAD 80/80 - 8 elem.
6d 34403410 ROD M16x1170 THREAD 80/80 - 9 elem.
6e 34403420 ROD M16x1300 THREAD 80/80 -10 elem.
6f 34403430 ROD M16x1430 THREAD 80/80 -11 elem.
6g 34403440 ROD M16x1580 THREAD 80/80 -12 elem.
6h 34403450 ROD M16x1690 THREAD 80/80 -13 elem.
6i 34403460 ROD M16x1820 THREAD 80/80 -14 elem.
7 34504940 SPRING MDE 34x16.3x2 DIN 2093
8 34504930 LONG NUT M16 UNI 5587
9 33400811 SHEATH 1"1/4x235 (6 BULBS)
10 34007500 HEX PLUG DA 11/4
11 34505080 THREADED BAR 12x100
12 34505050 THREADED BAR M12x80
13 34503360 STUD BOLT M16x75 THREAD 25/25
14 34503120 STUD BOLT M16x65 THREAD 25/25
16 34008970 PIN M16x135 FOR HANDLE
17 33202001 LOWER BOILER DOOR HINGE
18 34008990 PIN M12x37 TO FIX HINGE
19 34010370 CYLINDER LOCKING PIN
20 34010420 FUMES CHAMBER COLLAR FN.
21 33100790 BOILER FUMES CHAMBER FN.
22 33100810 FUMES CHAMBER HATCH FN.
23 34504430 STUD BOLT M10x50 THREAD 20/20
24
25
26a 37401640 COMP.CYLINDER FOR COMB.CHAMBER - 6 elem.
26b 37401640 COMP.CYLINDER FOR COMB.CHAMBER - 7 elem.
26c 37401650 COMP.CYLINDER FOR COMB.CHAMBER - 8 elem.

7
GN3
Casing (fig. 5)
61 37025080 COMPL.RIGHT FRONT SIDE UNIT
62 37025090 COMPL.LEFT FRONT SIDE UNIT
63 37025100 COMPL.COMPON.SIDE UNIT TYPE 1 (6-9-13 elem)
64 37025110 COMPL.COMPON.SIDE UNIT TYPE 2 (6-9-10-11-13-14 elem.)
65 37025120 COMPL.COMPON SIDE UNIT TYPE 3 (7-11-12 elem.)
66 31000210 STUD COUPLING CLIP
67 31207470 SIDE FIXING BRACKET
68 31132780 CASING SUPPORT PLATE
69 37025160 COMPL.UPPER FRONT PANEL
70 34000640 STUD FOR COUPLING
71
72
73 37025170 COMPL.LOWER FRONT PANEL
74 36500200 RUBBER CORE HITCH ART. 302 OVA
75 37025130 COMPL.COMPON.COVER TYPE 1 (6-9-13 elem.)
76 37025140 COMPL.COMPON.COVER TYPE 2 (6-9-10-11-13-14 elem.)
77 37025150 COMPL.COMPON.COVER TYPE 3 (7-11-12 elem.)
78 31134530 COMPLETE REAR WALL
79 38503630 FERROLI TYPE DOUBLE CORE HITCH
80 38200860 COMPLETE INSTRUMENT PANEL
81 38701280 COMPLETE KNOB FOR THERMOSTAT
82 36401210 PROBE TR2 540499 C.1500 PVC 3CNT
83 36401450 PROBE LS 541577 C.1500 PVC 110°C
84 36450010 CIRC.THERMOM.0-120°C CAP.1000
85 34100442 PERFORATED HINGE 25x24 TH.1.2
86 31207520 WIRING SUPPORT PLATE
87 35001091 DARK BROWN SCREEN-PRINTED PLUG 96x144
98 36100200 SWITCH UP.SPL60 ART. 6000.8.05
89 36200390 RED WARNING LIGHT SPL80 ART. 6029.2.00
90 36504800 CLOCK ART. FWZ-55 220v-50HZ
91 38504852 WIRING CONTROL PANEL
Fig. 5

8
GN3
Wiring diagram (fig. 6) Load loss diagram (fig. 7)
Fig. 6
BOILER Amm Bmm Cmm Dmm
GN3.06 600 618 520 98
GN3.07 600 618 520 98
GN3.08 750 785 520 115
GN3.09 750 785 520 115
GN3.10 950 1000 650 130
GN3.11 950 1000 650 130
GN3.12 1200 1280 650 160
GN3.13 1200 1280 650 160
GN3.14 1200 1280 650 160 Fig. 8
Key
TR1 1st burner stage adjuster thermostat
TR2 2nd burner stage adjuster thermostat
IB Burner switch
STB Safety thermostat
BZ1 1st stage burner hour counter
BZ2 2nd stage burner hour counter
B Burner plant panel
SB Burner safety warning light
Fig. 7
Fumes route (fig. 8)

9
GN3
INSTALLATION
The boiler must only be installed by qualified Personnel,
incompliancewiththeManufacturer’sinstructionsandall
the Laws and provisions which govern the matter.
Particular attention should be paid to safety Provisions
and those which govern the construction and location of
flues.
Base (fig. 9)
GN3 is a boiler which does not require a special base.
Just prepare a simple plinth which can be reinforced if
necessary,inordertofacilitateboilerpositioning.Insome
cases, particular installations may require a special
soundproofed base.
Boiler positioning (fig. 10)
Whenbuildingthebasecheck,afterboilerassemblywith
the
burner on the front door, that this latter can open without
theburnerhittingagainstthewalloranyotherboilerinthe
vicinity. Leave a free space of at least 100 mm from the
part towards which the door swings.
Afreespace should also be left in front oftheboiler. This
spaceshouldequalthelengthoftheboileritselfandallow
the cylinder to be removed from the combustion cham-
ber.
Burner
Electrical connection
Only qualified Personnel should complete the electrical
connections of the boiler and control panel or the burner
and plant connections.
Always connect the boiler to a good grounding system.
FERROLI S.p.A. declines all responsibility for damages
to persons and/or property caused by failure to connect
the appliance to a good grounding system.
Hydraulic connection
Thehydraulicconnectionsoftheboilershouldbeaccom-
plished in compliance with the indications given near
each union and those included in the Technical Brief.
Connectionmust becarriedout sothatthe pipesarefree
fromtensions.Itisobligatorytomountthesafetyvalveon
the heating circuit, as near as possible to the boiler but
without any obstruction or on-off device between the
boiler itself and the valve. Valve setting should be 3 bar.
The appliance is not supplied with expansion tank.
Connectionofthislattershall therefore be at the Installe-
r’s charge. Remember that pressure in the system when
cold, must be between 0.5 and 1 bar.
ELEMEN. A mm L mm
GN3.06 780 1010
GN3.07 910 1140
GN3.08 1040 1270
GN3.09 1170 1400
GN3.10 1300 1530
GN3.11 1430 1660
GN3.12 1560 1790
GN3.13 1690 1920
GN3.14 1820 2050
Normal base
Soundproofed base
Fig. 10
Fig. 9
Burner

10
GN3
Heating plant installation (fig. 11).
If there is a boiler recirculating pump, it is obligatory to
mount non-return valves upstream of the return union to
prevent parasitic circulations in the generators.
The recirculation flow rate must be between:
P P
and
5 45
P = Capacity of each boiler expressed in kcal/h
Burner operation must be linked to that of the recircula-
tion pump. It must only operate if the pump operates. As
anaccessory,aflowratemonitoringdeviceinserieswith
thermostatTHcanbemountedonthereturnpipeleading
to the boiler, downstream of the recirculating pump.
Flue connection
Alwaysconnecttheboilertoagoodflue,builtincomplian-
cewith the current provisions in force. Theduct between
theboilerandfluemustbemadeofsuitablematerial,i.e.
abletowithstandthetemperatureandcorrosion.Always
checkthesealinthejointingpointsandthermallyinsulate
the entire pipeline between the boiler and stack, to
prevent the formation of condensation.
Fig. 11

11
GN3
ASSEMBLY
Element assembly layout (fig. 12)
MOD. FRONT INT. ELEMENT INT. ELEMENT INT. ELEMENT REAR ELEMENT
ELEMENT WITH SH. FINS WITH LEGS
COD.3300455/2 COD. 3300491/0 COD. 3300458/0 COD. 3300457/0 COD. 3300456/0
GN3 06 11 3 1
GN3 07 12 3 1
GN3 08 1213 1
GN3 09 1214 1
GN3 10 1314 1
GN3 11 1315 1
GN3 12 1316 1
GN3 13 1317 1
GN3 14 1318 1
Fig. 12

12
GN3
Boiler shell
2. (Fig. 14) Clean the link housing with grease solvent.
Thoroughly clean the twin-cone housing on the rear
element using fine glass paper, then clean all the other
elements forming the boiler shell, if there is rust.
4. (Fig. 16) Mount the twin-cone in its housing, lightly
tapping it into place with a wooden mallet.
Fig. 13
Fig. 14
Fig. 15
3.(Fig.15)Cleanthelinkswithgrease solvent.Usingthe
package in the assembly kit, spread a light coating of
minium on the twin-cone and its housing, using a soft
brush.
Fig. 16
1. (Fig. 13) Use a 15 mm. wooden strip to shim the rear
element.
Now set a second strip in place, checking that it remains
stable throughout the assembly operations.

13
GN3
5. (Fig. 17) Using the packet of silicone included in the
assembly kit, spread a light strip of this product in the
retention seal housing (on both sides of the intermediate
element).
6.(Fig.18)StartingfrompointA,mounttheretentionseal
in its housing.
7.(Fig.19)Complywith the indicated route until comple-
ting this in point B.
Fig. 17 Fig. 19
Fig. 18

14
GN3
9.(Figs21-22-23)Insertrod1 through the two elements.
Mountnut3on the threaded end. Place stop pin 2 on the
rod hole near to the breadth of the two elements. Using
a 4 wrench, tighten the unit until the two elements have
been perfectly joined.
Fig. 20
Fig. 21
Fig. 22
Fig. 23
8. (Fig. 20) Place the first intermediate element near the
rearone,afterhavingprepareditasdescribedfortherear
element itself (points 3 - 4 - 5 - 6 and 7). Also add the
retention seal from point C through to point D.

15
GN3
Fig. 24
Fig. 26
as to crush them.
13.(Fig.26)Mount thefollowingpartsonthefrontsideof
the boiler shell:
* Four stud bolts 1 (M12x80) of the upper door.
* Two stud bolts 2 (M12x135) of the door closing handw-
heels.
* Door support 3, fixing it with the two screws 4.
Place the cylinder (6) in the combustion chamber
according the indications in fig. 8 (complying with
dimensionintable)insertthepininthecylinderhole.
14. (Fig. 27) Mount distribution pipe 1, if necessary in
parts interspaced with a seal 2.
Checkthatthenotchontheflangepointsupwardssothat
the water through holes are pointing downwards. Mount
the second seal 2, flange 3, washers 4 and then tighten
with nuts 5.
10.Proceed asdescribedin thepreviousparagraph until
all the elements forming the boiler shell have been
mounted.
11. (Fig. 24-25) Mount the four rods “1”, the six Belleville
washers“2”intherearpartoftheboilershell,thentighten
nuts “3”.
12.(Fig. 24) Mount the following parts on the rear side of
the boiler shell:
* Three stud bolts 4 (M12x100) of the smokebox.
* Four stud bolts 5 (M16x65) of the upper flange.
* Four stud bolts 6 (M16x75) of the lower flange.
MountingtherodswiththeBellevillewashers(fig.25)
NOTE:Thespringsmustbemountedopposite,asshown
inthedrawing, andthenutsmust notbefixedso strongly
Fig. 25 Fig. 27

16
GN3
C2
C2
C2 C2 B4
B3
C2
C2
B4
C2
C2
C2
C2
C2 C2
C2 C2 B3
A1
A1
A1
A0
A0
A0
C2 B3
B3
B4
C2
B3
B4
A2
1035
902
769
1833
1700
1567
1434
1301
1168
A2
A2
GN3.06
GN3.07
GN3.08
GN3.09
GN3.10
GN3.11
GN3.12
GN3.13
GN3.14
447
490.0
SECTION A0 A1 A2 C2 B3 B4 Spring Clip
PART. Nr. 3844524/0 3844523/0 3844522/0 3422356/0 3844525/0 3844526/0 3430032/0
GN3.06 1 1 1
GN3.07 1 1 1
GN3.08 1 1 1 2
GN3.09 1 1 1 2
GN3.10 1 2 1 3
GN3.11 1 2 1 3
GN3.12 1 3 1 4
GN3.13 1 3 1 4
GN3.14 1 4 1 5
Set of 8 spring clips: part. N°3980273/0
Composition Water Distribution Pipe
Fig. 27a
Spring clip
HOLE
Example for GN3.09
A1 = Flange section
with 1 hole
C2 = Middle section
with 2 holes
B4 = End section
with 4 holes

17
GN3
16.(Fig.29)Mountflange1afterhavinginterspacedseal
2, washers 3. Now tighten with nuts 4. 18. (Fig. 31) Mount the upper front door on the four stud bolts 1 and lock it in place with the relative nuts 2.
Fig. 29 Fig. 31
17.(Fig.30)Mountthesmokeboxonthethreestudbolts
4 (Fig. 24), locking them in place with nuts 3.
15. (Fig. 28) Using the relative pump, connect to union 1
and let water under pressure into the boiler (8 bar). Wait
a few minutes before checking that there are no leaks.
Now check that the fumes seal between the elements is
correct.
Ferroli S.p.A. declines all responsibility for damage to
persons or property caused by fumes and water leaks
from the boiler due to assembly errors or negligent seal
inspections.
Fig. 28
Fig. 30

18
GN3
22. (Fig. 35) The boiler shell can be supplied already
assembled. In this case, it will be dispatched from the
factory on a pallet.
Remove bolts 1 fixing it to the pallet and place it in its
permanent installation position. Now mount the various
panels.
20. (Fig. 33) Fix the door with knobs 7 which should be
screwed on to stud bolts 2 (Fig. 26) and with knobs 8
already fitted with stud bolts.
CASING ASSEMBLY
19. (Fig. 32) Mount the lower door of the burner, hinging
it to support 3 (Fig. 28) with the relative pins 1 and split
pins 2.
Fig. 32
Fig. 33
21.(Fig.34)Covertheboilershellwiththesupplied sheet
ofmineralwool,fixing ittorods1(Fig.24)andusingclips
7 included in the assembly kit.
Fig. 34
Fig. 35

19
GN3
24. (Fig. 37) Prepare the right and left side panels,
choosing the number of panels according to the size of
the boiler.
22 a. (Fig. 35a) Mount rear panel 1 of the smokebox, on
the three stud bolts without fixing it.
Fig. 35a
23.(Fig.36)Mountbar2onupperrods1 (Fig.24)and fix
it with nuts 3.
ABCDE
6 elem. 910 536 — — —
7 elem. 1040 666 — — —
8 elem. 1186 812 406 406 —
9 elem. 1316 942 406 536 —
10 elem. 1446 1072 536 536 —
11 elem. 1576 1202 666 536 —
12 elem. 1706 1332 666 666 —
13 elem. 1852 536 536 536 406
14 elem. 1982 1608 536 536 536
Fig. 37
13-14 element. 8-12 element. 5-7 element.

20
GN3
25.(Fig.38)Connectthepanelstogetherusingscrews1,
washers 2 and nuts 3, reinforcing their lower part with
bars 4 fixed with screws 5.
26.(Fig.38)Slackenknobs8ontherightsideoftheboiler
together with the two screws 4 fixing door support 3.
27.(Fig.40)Insertthecompleterightsidepanelbetween
door support 3 and the boiler shell, checking that the
machined slots fit into their correct positions.
Now tighten screws 4 and knobs 8.
Fig. 39
Fig. 40
Fig. 38