Ferroli GN2 N User manual

INSTALLATION AND OPERATING
INSTRUCTIONS
GN2
HIGH EFFICIENCY
CAST IRON BOILER
FOR LIQUID and/or
GAS FUELS

2GN2
INDEX
1. Technical information .............................................................................................................................. page 3
2. Dimensional and technical characteristics .............................................................................................. page 3
3. Packing and dispatch ........................... .................................................................................................. page 5
4. Boiler assembly....................................................................................................................................... page 6
5. Shell assembly ....................................................................................................................................... page 11
6. Installation ............................................................................................................................................... page 19
7. Inspections and adjustments................................................................................................................... page 20
8. Maintenance............................................................................................................................................ page 21
9. Boiler parts .............................................................................................................................................. page 22

3
GN2
Q (m3/h)
Fig. 2
Technical information
1.01 Introduction
GN2 is a new high efficiency heat generatorproducing hot water for heating purposes. It can operate with either
a liquid and/or gas fuel fired burner 1°or 2°stage.
The boiler unit consists of cast iron parts assembled by steel rods and links, the shape of which has been particularly
designed to achieve optimum fin distribution. This ensures high thermal efficiency and consequently high energy
savings. The boiler is insulated by a thick layer of glass wool to reduce heat loss to the minimum.
Fig. 1
2. Dimensional and technical
characteristics
2.01 Load loss characteristics (fig. 2)
Theloadlossesofthehydrauliccircuitpertainingtoeach
boiler model, are specified in the following diagram
which refers to the water flow rates corresponding to
temperatures between 10 and 20°C.
1.02 Function of the adjusting and safety devices
Manually reset safety thermostat 3 (fig. 1)
Thisisactivatedwhenthetemperatureintheboilerduringtheheatingphasereachesavaluebeyondwhichadangerous
condition could be created.
Boiler regulating thermostat 5 (fig. 1)
Used to adjust the temperature in the boiler by means of its adjuster knob. This thermostat controls the 1°or
2°stage burner. In the case of use of 1°stage burner, you must not connect the B2 block (2°stage burner).
Ambient thermostat
This is not standard supply, but can be mounted at the Installer’s charge.
It is connected in series with the regulating thermostat and contemporaneously controls both the burner and the plant
circulator during the heating phase. It is advisable to install this thermostat for greater comfort and energy savings.
Key
1Thermometer
2Arrangement for automatic control
3Mains switch
4Overheat cut-off thermostat
5C.H. boiler thermostat
∆p (mbar)

4GN2
2.02 Dimensional and technical brief (fig. 3 - table 1)
NOTE: - The maximum operational temperature of the plant heating water is 90°C.
Table 1
Fig. 3
Key
a1 - PLANT DELIVERY ND 80 - 3"
a2 - PLANT RETURN ND 80 - 3"
a3 - 3/4" BOILER DRAIN
A600
1086
867
84
726
Ø
375
B
a1
a2 a3
30
090
60
120
60
0
°C
4
4
4
4
4
4
4
4
4
4
Working
pressure
bar
670
780
890
1000
1110
1220
1330
1440
1550
1660
A
130
130
130
150
150
150
150
150
150
150
B
180
180
180
200
200
200
200
200
200
200
Ø
0,4
0,4
0,4
0,4
0,4
0,4
0,4
0,4
0,4
0,4
Combustion
chamber
load loss
∆p mbar
63
77
91
104
118
132
146
160
174
187
Combustion
chamber
volume
dm
3
Water
load
losses
0,5
0,8
1,8
2,2
2,6
3,2
4
4,5
∆t20
2,8
3,4
4,8
6,5
8,5
11
13
16
19
23
∆t 10
310
361
412
463
514
565
616
670
725
780
Weight
of unit
kg.
Model
GN2 05
GN2 06
GN2 07
GN2 08
GN2 09
GN2 10
GN2 11
GN2 12
GN2 13
GN2 14
Model
GN2 05
GN2 06
GN2 07
GN2 08
GN2 09
GN2 10
GN2 11
GN2 12
GN2 13
GN2 14
128,8
153,3
177,7
202,2
226,6
251,1
275,5
300
324,4
348,8
Heat and
D.H.W.
(gross)
gas
Max.
116
138
160
182
204
226
248
270
292
314
Heat and
D.H.W.
(net)
gas+oil
Max.
88,8
100
122,2
138,8
155,5
172,2
188,8
205,5
222,2
238,8
Heat and
D.H.W.
(gross)
gas
Min.
80
95
110
125
140
155
170
185
200
215
Heat and
D.H.W.
(net)
gas+oil
Min.
73
87
101
115
129
143
157
171
185
199
Potenza
termica
Min.
105
125
145
165
185
205
225
245
265
285
Heat and
D.H.W.
output
5
6
7
8
9
10
11
12
13
14
N°
element
49
57
65
73
81
89
97
105
113
121
Water
capacity
dm
3
505
615
725
835
945
1055
1165
1275
1385
1495
Combustion
chamber
lenght
mm
400
400
400
400
400
400
400
400
400
400
Combustion
chamber
dimension
Ømm

5
GN2
Fig. 4
1. Boiler unit
5. Accessory kit
2. Shell
3. Control panel
4. Elements
Boiler GN2 can be supplied in two versions, with the
boiler unit either assembled or in parts.
Three packs will be dispatched in the first case:
1. Boiler unit
2. Shell
3. Control panel
In the second case, there will be the following 4 packs:
2. Shell
3. Control panel
4. Kit of parts forming the boiler unit
5. Kit of accessories with which to mount the elements.
3. Packing and dispatch (fig. 4)

6GN2
4.01 (Fig. 5) Use a 12 mm strip of wood to shim the rear
element.
Now rest it on a second strip, checking that it remains
stable throughout the assembly operations.
4. Boiler assembly
Fig. 5
Fig. 6
Fig. 7
4.03(Fig.7) Using the tin in the assembly kit, spread
a thin layer of minium on the link and its housing,
using a soft brush.
Fig. 8
4.04 (Fig. 8) Mount the link in its housing, tapping lightly
with a wooden mallet.
4.02(Fig.6) Use fineglasspapertothoroughlycleanthe
housing of the link on the rear element and of all other
elements forming the boiler unit.
Boiler unit

7
GN2
Fig. 10
Fig. 11
Fig. 12
Fig. 9
4.05(Fig.9)Usingthetubeofsiliconeintheassemblykit,
spread a small amount of this product in the retention
seal housing.
4.06 (Fig. 10) Near the first intermediate element to the
rear element.

8GN2
ROD GN2 12 ELEM. LG. TOT. 1290
ROD GN2 12 ELEM. LG. TOT. 1290
ROD GN2 14 ELEM. LG. TOT. 1510
Fig. 16
Fig. 13
4.07 (Figs 11 - 12 - 13) Insert rod 1 between the two
elements, mount nut 3 on the threaded end, place stop
pin 2 ontheholeoftherodnearthepairofelementsthen
clamp the unit together using a N°4 wrenchuntil the
two elements have been perfectly joined together.
4.08 Proceed as described in the previous paragraph
until all the elements forming the boiler unit have been
mounted.
Fig. 14
4.09 (Figs 14 - 15 - 16) Mount the four rods «1», the
Belleville washers «2» as shown in fig. 15 and finally
torque nuts «3».
Fig. 15
Mounting the rods with the Belleville washers.
NOTE: The Belleville washers must be mounted in an
opposed way as shown in the diagram while the nuts
must be fixed in order to prevent them from being
crushed.
For GN2 boilers with 12 - 13 - 14 elements, mount the
rods with sleeve part 1, remembering to fully tighten the
sleeve thread on both sides.

9
GN2
Fig. 17
Fig. 19
Fig. 20
4.10 (Fig. 17) Using the relative pump, connect to
coupling 1 and pump in water under pressure (8 bar).
Wait a few minutes before checking that thereareno
leaks. Now check that smoke retention between the
elements is correct.
IndustrieFER S.r.l.declinesallresponsibilityfordamage
to persons or property caused by water or smoke leaks
from the boiler due to incorrect assembly or failure to
check retention.
Fig. 18
- Mount the following parts ontherearsideoftheboiler:
- four stud bolts (1)
- eight stud bolts (2) with their relative flanges (3) and
seals (4)
- Mount the collar (5) with the screws (6) and spread a
small amount ofsilicone(includedinthekit)aroundthe
retention seal housing on the rear end.
4.11 (Fig. 19) Mount all parts on the front side as shown
in the diagram.
4.12 (Fig. 20) Assembly detail of the servicing door and
burner hatch.

10 GN2
1
4.13 (Fig. 21) Cover the boiler unit with the supplied mineral wool insulation.
4.14 (Fig.22) Theboiler unitcan alsobe suppliedalready assembled.It willbesentstraightfromthefactoryonapallet.
Remove bolts 1 fixing the boiler to the pallet and place the boiler itself in its final installation position. Now proceed by
mounting the various panels.
Fig. 21
Fig. 22

11
GN2
2
1
4.15(Fig. 23)Whenpositioningtheboilerunit,check that after burner assembly the frontdoor isabletoopenwithout
striking against the wall or any other nearby boiler, i.e. leave a space of at least 100 mm as shown in the figure.
5. Shell assembly
Fig. 24
5.01 (Fig. 24) Mount rear panel 1 on stud bolts 2 without fixing it.
Fig. 23

12 GN2
13÷14 el.
9÷12 el.5÷8 el.
5.02 (Fig. 25) Prepare the right and left sides, choosing the number of side panels according to the boiler dimensions
(see table)(fig. 25).
Fig. 25
A
1056
1026 30
A440 L
A440 L 440
GN2.05
GN2.06
GN2.07
GN2.08
GN2.09
GN2.10
GN2.11
GN2.12
GN2.13
GN2.14
580
690
800
910
1020
1130
1240
1350
1460
1570
580
690
800
910
580
690
800
910
580
690
5
6
7
8
9
10
11
12
13
14
MODEL L A Number
element

13
GN2
1
5.03(Fig.26)Connect thepanelstogetherusingscrews1,washers2andnuts 3,reinforcing theirlowerpartwithstrips
4 fixed with screws 5.
Fig. 27
Fig. 26
5.04 (Fig. 27) Slacken nuts 1 on the right-hand side of the boiler.

14 GN2
2
1
1
5.05(Fig.28)Insertthecompleterightsidebetweenrods
1 and the boiler unit, checking that the machined slots
fit into their correct position. Now torque nuts 2.
5.06 (Fig. 29) Fix the right-hand side to the rear panel
using screws 1.
Fig. 28
Fig. 29

15
GN2
2
1
5.09 (Fig. 31) Fix front lower panel 2 with the four self-threading screws 1.
Fig. 31
5.08 Now fix the left-hand side to the rear panel using screws 1 in the same way as right side assembly (fig. 29).
5.07 (Fig. 30)Slacken nuts 1 on the left-hand side of
the boiler and mount the left-hand side part, checking
thatthemachinedslotsfitintotheircorrectposition.Now
torque nuts 1.
Fig. 30

16 GN2
Fig. 32
5.10 Overturn the capillary tube of water gauge 6 (fig. 1) and screw its union to the relative sheath on the front part
of the boiler unit (fig. 32).
Fig. 33
5.11 (Fig. 33) Fix the upper panel 1, according to the
dimensionoftheboiler.Preparethefrontlowerpannel2,
fixingthegrommet3forthecableoftheburner.Fixangle
4 on the both sides. Fix the safety wiring box 5 on upper
angle.

17
GN2
Fig. 35
Fig. 34
5.13 (Fig. 35) Fix angle 1 (right-left), assemble the pannel 2 and the control pannel. Fix safety box 3 by self-threading
screw 4 inside the angles 1. Insert the board on the pannel 2 and fix sideways with the screw 5 Cover the board with
the safety cap 6.
NOTE: The electrical connections between the burner and boiler are at the charge of Qualified Personnel.
5.12 (Fig. 34) Overturn the capillary tubes and insert the 3 probes 1 into sheath 2 (- adjuster thermostat - safety
thermostat - thermometer).
12

18 GN2
1
2
5.14(Fig.36)Overturn the electrical mains cable,allowittopassundertheboilerunitandfixitwiththerelativescrews
2 on to core hitch 3 on the rear wall.
Fig. 36
Fig. 37
5.15 (Fig. 37) Mount upper front panel 1.
1
A

19
GN2
Key Fig. 38
6. Installation
Boiler installation must only be carried out by Qualified Personnel in compliance with the Manufacturer’s instructions
and according to all laws and provisions in merit.
You are particularly advised to comply with all safety regulations governing the construction and location of smoke
stacks.
6.01 Electrical connection
Connectthecirculator,theburnerandtheambientthermostat(ifused)accordingtotheindicationsappliedtotherelative
cables and in compliance with the enclosed wiring diagram (fig. 38). Always install a bipolar circuit-breaker between
themainssocketandthe appliance.Theopeningbetweenthe contactsof thiscircuit-breaker should be atleast3mm
and it should be equipped with fuses.
Alwaysconnecttheappliancetoagoodgroundingsystem.IndustrieFERROLIS.p.A.declinesallresponsibility
for damages to persons or property caused by failure to connect the appliance to a good grounding system.
230V 50Hz
L
B2
B1
N
CA
2ST
3421
IL
56789101112
N
B5
T8
T7
T6
B4
T1
T2
S3
N
L1
TS
11
TR2 12
22
21
TR1
IL
230V
50Hz
CA
1
L
TS
2
3
5
L1
T1
T2
N
T6
B5
B4
S3
B1
T8
T7 B2
2ST
12
10 116
8
9
22
21
TR1 12 TR2
11
7
4
IL = Main switch
CA = Contact auxiliary
TR1 = Boiler thermostat 1 stage
TR2 = Boiler thermostat 2 stage
TS = Safety thermostat
B1 = Burner 1 stage
B2 = Burner 2 stage
2ST = Contact 2 stage
Remove the line if room
thermostat is fitted

20 GN2
6.02 Connection to the water main
Connect the appliance to the water main in compliance with the indications given near each coupling and according
to those shown in figure 2 of this handbook.
Connectionmustensurethatthepipesarefreefromtensions.Itisessentialtomountasafetyvalveontheheatingcircuit
as near as possible to the boiler without any obstructions or on-off device between this and the valve itself.
The appliance is not supplied with expansion tank. Connection to this device must therefore be carried out by the
Installer.
6.03 Connection to the smoke stack
Always connect the boiler to a good smoke stack built in compliance with the current provisions in merit. The duct
between the boiler and the smoke stack must be made of a suitable material, i.e. able to withstand the temperatures
and rust resistant. Always check that all joints are well sealed and thermally insulate the entire duct between the boiler
and stack in order to prevent condensation from forming.
7. Inspections and adjustments
7.01 Before initial ignition
Before switching on for the first time, it is advisable to check that:
a) the system has been filled at the correct pressure and is well vented;
b) there are no water or fuel leaks;
c) the electric power supply is correct;
d)theentiresmokeducthasbeencorrectlymadeandthat ithasnotbeeninstalledtoonearorthroughinflammableparts;
e) that there are no inflammable substances near the appliance;
f) that the burner is proportional to the boiler rating;
g) that the water on-off valves are open.
7.02 Initial ignition
Having carried out the preliminary inspections, proceed with the following ignition manoeuvres:
1. Open the fuel on-off valve.
2. Adjust thermostat 5 (fig. 1) to the required value.
3. Close the switch upstream of the boiler and switch 4 (fig. 1) on the control panel.
The burner will start and the boiler begin to operate.
7.03 After initial ignition
After having switched on the boiler for the first time, it is advisable to check that:
a) the burner operates correctly. This inspection should be made with the relative instruments;
b) the thermostats operate correctly;
c) water circulates around the system;
d) the fumes are completely disposed of through the stack.
7.04 Switching off the boiler
For short periods at a standstill, just use switch 4 (fig. 1) on the control panel.
Iftheboileristo remain inoperative for alongperiod,besides operating switch 4, it isalsoessentialtoshut the fuel on-
off valve.
When the boiler remains for long periods at a standstill during the winter period, prevent damage from freezing by
pouring antifreeze fluid into the system or by completely emptying the boiler.
The boiler should only be serviced by Qualified Personnel.
It is advisable to have the appliance checked at least once a year, before the winter season. Besides the state of
cleanlinessoftheboiler,thisinspectionshouldalsoincludecorrectoperationofallboilercontrolandsafetydevicesplus
the burner.