Ferroli GN4 N User guide

Instructions for
installation
and operation
HIGH PERFORMANCE
CAST IRON BOILER
FOR LIQUID and/or
GASEOUS FUELS
GN4

2 GN4

3
GN4
CONTENTS
General ...................................................................................................................................................... 4
Characteristics ........................................................................................................................................... 5
Installation ................................................................................................................................................ 11
Assembling the boiler body ...................................................................................................................... 14
Assembling the casing ............................................................................................................................. 21
Checks ..................................................................................................................................................... 25
Regulation ................................................................................................................................................ 25
Maintenance............................................................................................................................................. 26

4 GN4
Packaging (ill. 2)
The GN4 boiler is split into four packages as fol-
lows:
1. Casing
2. Control panel
3. Elements making up the boiler body
4. Accessory kit for assembling the elements
N.B. The tools for assembly of the elements are
available from your area agent.
GENERAL
fig. 2
fig. 1
1. Casing 2. Control panel
3. Elements 4. Accessory kit
Key
1Electronic control unit (not supplied)
2Burner 1st stage operation hour meter
3Burner 2nd stage operation hour meter
4Burner lock warning light
5Boiler thermometer
6Safety thermometer
7Burner switch and indicator light
8Burner 2nd stage regulation thermostat
9Burner 1st stage regulation thermostat
Description
The GN4 boiler is a new high performance heat
generatordesignedtoproducehotwaterforcentral
heating systems, operating with either liquid fuel
and/or gas burners.
The boiler body consists of cast iron elements
assembled with steel cone inserts and tie rods.
Particularattentionhasbeenpaidtotheprofilewith
optimum division of the fins ensuring high thermal
efficiency and considerable energy savings.
Theboilerisinsulatedwithathicklayerofrockwool
to minimise heat loss.
1
2
3456789

5
GN4
CHARACTERISTICS
Technical specifications (ill. 3)
fig. 3
Key
1. Electronic control unit (optional)
2. Burner 1st stage operation hour meter
3. Burner 2nd stage operation hour meter
4. Burner lock warning light
5. Boiler thermometer
6. Safety thermostat
17
A2
23456 8 9
11 10
A1
B2
B1
850
A
463
1279
898
908
83
463
281.5
Ø D
7
8
9
10
11
12
13
14
N°
elements
217
270
324
388
452
516
600
695
Max.
200
250
300
360
420
480
560
650
Max.
heat output
kW
Delivered heat output
kW
4
4
4
4
4
4
4
4
Operating
pressure
bar
1040
1170
1300
1430
1560
1690
1820
1950
A
mm
840
950
1060
1170
1280
1390
1500
1610
Body
weight
kg.
Combustion chamber
pressure drop
∆p mbar
0,5
0,8
0,7
1,0
1,4
1,7
2,6
3,5
120
150
180
215
250
290
330
390
Min.
128
160
192
229
266
309
352
416
Min.
Model
GN4.07/200
GN4.08/250
GN4.09/300
GN4.10/360
GN4.11/420
GN4.12/480
GN4.13/560
GN4.14/650
180
180
250
250
250
250
250
250
D
Ø
Water
pressure drop
∆p mbar
∆t 20°
20
30
42
54
65
77
88
100
Model
GN4.07/200
GN4.08/250
GN4.09/300
GN4.10/360
GN4.11/420
GN4.12/480
GN4.13/560
GN4.14/650
143
163
183
203
223
243
263
283
Water
content
dm
3
880
1010
1140
1270
1400
1530
1660
1790
Length of
combustion
chamber
L mm
500
500
500
500
500
500
500
500
Dimensions of
combustion
chamber
Ø mm
172
198
220
250
270
300
325
350
Combustion
chamber
volume
Ø mm
7. Burner switch and indicator light
8. Burner 2nd stage regulation thermostat
9. Burner 1st stage regulation thermostat
10. Pressure inlet fitting in combustion chamber
11. Inspection window for flame control
A1. Central heating flow outlet DN 80 - 3" gas
A2. Central heating return inlet DN 80 - 3" gas
B1. Low temperature central heating flow outlet DN 80 - 3" gas
B2. Low temperature central heating
return inlet DN 80 - 3" gas

6 GN4
Casing (ill. 4)
fig. 4
15 13
16
1
2 3
26-27
5
7
8
4
6
23
22
21
20
19
18
17
24
25
28
12 11 10
14 9

7
GN4
13703465/0 Front left side panel, complete
23703466/0 Top front panel, complete
33703467/0 Bottom front panel, complete
43703464/0 Front right side panel, complete
53702759/0 Type 1 sectional side panel, complete
63120747/0 Bracket, side panel fixing
73702760/0 Type 2 sectional side panel, complete
83702761/0 Type 3 sectional side panel, complete
93100021/0 Pin coupling spring
10 3114204/0 Casing rear wall
11 3400064/0 Coupling pin
12 3650363/1 Dual cable clamp
13 3702766/0 Type 3 complete sectional cover
14 3114203/0 Casing support rear plate
15 3702765/0 Type 2 complete sectional cover
16 3702764/0 Type 1 complete sectional cover
17 3500338/0 Screen-printed plug
18 3620039/0 Red pilot light
19 3645001/0 Thermometer 0-120 °C
20 3640145/0 Safety thermometer
21 3610020/0 Unipolar switch
22 3670128/0 Complete knob for thermostat
23 3640121/0 Regulating thermostat
24 3650480/0 Clock
25 3120752/0 Wiring support plate
26 3820090/0 Control panel
27 3850485/2 Wiring
28 3410044/2 Hinge

8 GN4
fig. 5
Boiler body (ill. 5)
75 73 72 71 70 69
47 48 49 50 51 52
55 56 57
41-42
45
44
43
63
6261
64
58 59-60
46
65
78
74
53 54
76 77
66
67
68
79
69
51

9
GN4
41 3320252/0 Boiler burner door, finished
42 3800703/0 Burner door, complete
43 3535293/0 Mica disk Ø44 - Thickness 0.5
44 3340028/0 Pressure test point
45 3400885/0 Inspection window flange
46 3215253/0 Flange Ø340 - thickness 12
47 3401067/1 Door handle
48 3450582/0 Stud bolt M16x76
49 3410059/0 Boiler door hinge
50 3532088/0 Burner holder insulation
51 3360132/0 Plug
52 3300568/0 Front element, finished
53 3532086/0 Fibre piece 8x1600
54 3532085/0 Fibre piece 8x825
55 3420508/0 Cone insert
56a 3440339/0 Tie rod M16x910
56b 3440340/0 Tie rod M16x1040
56c 3440341/0 Tie rod M16x1170
56d 3440342/0 Tie rod M16x1300
56e 3440343/0 Tie rod M16x1430
56f 3440344/0 Tie rod M16x1560
56g 3440345/0 Tie rod M16x1690
56h 3440346/0 Tie rod M16x1820
57 3300569/0 Intermediate element, finished
58 3300570/0 Rear element, finished
59 3840761/0 Rear diffuser pipework L 352.5
60 3840762/0 Rear diffuser pipework L 482.5
61 3422406/0 Intermediate diffuser pipe
62 3840760/0 Front diffuser pipework
63 3450336/0 Stud bolt M16x75
64 3844366/1 Flanged pipe L 180
65 3450312/0 Stud bolt M16x65
66 3844763/1 Flanged pipe with knob
67 3535291/0 Gasket
68 3450584/0 Plug
69 3401156/0 Blind flange
70 3510018/0 Gasket Øe 133 - Øi 90 - Thickness 4
71 3310089/0 Smokebox
72 3450493/0 Thick nut M16
73 3450494/0 Spring MDE 34x16.3x2
74 3430022/0 Insulating fixing spring
75 3340081/1 Sheath 1" 1/4x235
76 3532084/0 Fibre piece 8x740
77 3532087/0 Fibre piece 8x2730
78 3450583/0 Threaded bar M12x130
79 3370086/0 Gasket

10 GN4
Wiring diagram (ill. 6)
fig. 6
Key
TR1 Burner 1st stage regulating
thermostat
TR2 Burner 2nd stage regulating
thermostat
IB Burner switch
STB Safety thermostat
BZ1 Burner 1st stage hour meter
BZ2 Burner 2nd stage hour meter
BBurner central panel
SB Burner safety light
Flue gas path
fig. 7
TR1 TR2
SB
STB
BZ1 BZ2
IB
123456789101112
B
230 V 50 Hz
LN
LN
105

11
GN4
Positioning the boiler (ill. 10)
Whenconstructingthebase,ensurethatafterassembly
of the boiler with the burner on the front door, the door
can open without the burner hitting the wall or another
boiler. In other words, leave a space of at least 100 mm
on the door-opening side.
fig. 8
Boiler installation must be carried out by qualified
personnel only, following the manufacturer’s instruc-
tions and in compliance with all relevant laws and
regulations.
In particular, regulations regarding safety and the
constructionandlocationoffluesshouldbeobserved.
Base (ill. 9)
The GN4 boiler does not require any special kind of
foundation; a simple concrete base is sufficient, rein-
forced if necessary with metal plates to facilitate
positioning of the boiler. In some cases, for special
types of installation, a special acoustically insulated
base may be required.
fig. 9
Ordinary base
Acoustically insulated base
Elements
GN4.07
GN4.08
GN4.09
GN4.10
GN4.11
GN4.12
GN4.13
GN4.14
A mm
910
1040
1170
1300
1430
1560
1690
1820
L mm
1140
1270
1400
1530
1660
1790
1920
2050
850
700
A L
Flat irons,
120 mm wide
Sealing
(optional)
Concrete
Reinforcement
Acoustic insulation
Base
80
20
20
100
mm
550==
Burner
50
Electrical connection
Completion of the electrical connection between the
control panel and boiler and the connections between
the burner and heating system will be the responsibility
of qualified installation personnel.
The boiler must be connected to an efficient earth
installation.
Ferroli S.p.A. declines all responsibility for injury to
persons and/or damage to property caused by failure to
connect the appliance to an efficient earth installation.
Water connection
Connecttheboilerwater circuit according to the instruc-
tions given near each coupling and in the technical
specifications.
Ensure that the pipes are not under tension. A safety
valve must be fitted in the central heating circuit as near
as possible to the boiler, ensuring there are no obstruc-
tions or gate valves between the valve and boiler.
Pressure must be 3 bars.
The appliance is not supplied with expansion tank and
installationmusttherefore beperformedbytheinstaller.
Remember that when cold, appliance pressure should
be between 0.5 and 1 bars.
INSTALLATION

12 GN4
fig. 10
Connection to low temperature central heating
system (ill. 10)
The delivery circulation flow must be calculated
with a ∆t of between 10 °C and 30 °C.
Delivery Return

13
GN4
Connection to traditional central heating sys-
tem (ill. 11)
Aboilerrecirculationpumpmustbefittedtoprevent
faulty circulation in the generators. Also, the non-
return valves must be fitted upstream of the return
connection.
The recirculation flow (in m3/h) must be between:
PP
and
652
P = Power of each boiler expressed in kW.
fig. 11
Return
Delivery
Flue connections
The boiler should be connected to an efficient flue
constructedinaccordancewithcurrentregulations.
The pipe connecting the boiler to the flue must be
made of suitable material, in other words resistant
totemperatureandcorrosion.Particularcareshould
be taken over joint seals, ensuring thermal insula-
tionbetweenboilerandfluetoavoidcondensation.
The burner must be connected to the recirculation
pump.Itwillcomeononlyifthepumpisworking.As
an accessory, a flow control device in series with
the thermostat TH can be fitted on the return to the
boiler, downstream of the recirculation pump.
Example: for GN4.09 (300 kW)
recirculation flow must be between
300 = 50 m3/h (13,9 l/s)
6
300 = 5,8 m3/h (1,6 l/s)
52
and

14 GN4
4(fig. 16) Fit the cone insert into its housing,
knocking it in with a wooden hammer.
fig. 16
fig. 13
fig. 15
fig. 14
2(fig. 14) Clean the cone insert housings with
solvent for grease. Using fine sandpaper, thor-
oughlycleantheconeinserthousingontherear
element and then on all the other elements
making up the boiler body in order to eliminate
any rust.
1(fig.13)Resttherearelementagainstawooden
batten, ensuring that it is stable for the whole of
the assembly operations.
3(fig. 15) Clean the cone inserts with solvent for
grease.Usingasoftbrush,spreadathinlayerof
red lead (contained in the assembly kit) on the
cone insert and its housing.
ASSEMBLING THE
BOILER BODY

15
GN4
8(fig. 20) Position the first intermediate element
next to the rear element, after preparing it as
described for the rear element (points 3 - 4 - 5 -
6 - 7).
fig. 20
fig. 17
6(fig. 18) Starting from point A, fit the sealing
gasketinitshousing.Followthepathshownuntil
you reach point B.
5(fig.17)Usingthesiliconeincludedintheassem-
bly kit, spread a thin strip around the sealing
gaskethousing(onbothsidesoftheintermediate
element).
7(fig. 19) Add the other two pieces C.
fig. 19
C
C
fig. 18
AB

16 GN4
10 Proceedasdescribedintheaboveparagraphuntilall
the body elements have been fitted.
11 (fig. 24-25) Fit the four tie rods “1”, the six Belleville
washers “2” in the rear part of the boiler body and
then tighten the nuts “3”.
12 (fig. 24) Fit the following on the rear side of the boiler
body:
•Thefourstudbolts“4”(M12x130)ofthesmokebox.
• The four stud bolts “5” (M 16x65) of the upper
flange.
•Thefourstudbolts“6”(M16x75)ofthelowerflange.
FittingthetierodswiththeBellevillespringwashers
(fig. 25).
N.B.: The washers must be fitted as shown in the draw-
ing (opposed) and the nuts must not be tightened
too hard in order not to squash the washers.
9(fig. 21-22-23) Insert the tie rod 1 between the
two elements, fit the nut 3 on the threaded end,
position the stop pin 2 on the tie rod hole at the
end of the two elements and, by means of the
spanner4,tightentheunituntilthetwoelements
are perfectly joined.
fig. 23
fig. 22 3
41
fig. 21
1
1
1
2
fig. 24
5
613
32
1
4
5

17
GN4
14 (fig. 27) Connect the pump to fitting 1 and let
water in at a pressure of 8 bars. Wait a few
minutes before checking for leaks. Check that
the flue gas seal between the elements is cor-
rect.
Ferroli S.p.A accepts no liability for damage
to property or injuries to persons caused by
leaks of water and flue gas from the boiler
due to assembly errors or inaccurate seal
checks.
fig. 25
13 (fig.26)Fit thefourstud bolts1with hinges2on
the front side of the boiler body.
10 elements • Total length 1300
11 elements • Total length 1430
12 elements • Total length 1560
13 elements • Total length 1690
14 elements • Total length 1820
For boilers with 10 - 11 - 12 - 13 - 14 elements, assemble the
tie rods with the sleeve 1.
fig. 27 1
fig. 26
12

18 GN4
Composition of water diffuser pipe
11 Elements
12 Elements
13 Elements
10 Elements
9 Elements
14 Elements
1635 C2
C2
A
AC2 C2
1765
C2
C2 B4
B3
C2
B4
C2
C2
1245 B3C2 C2
1375
A
A
A1505
C2 B3C2
C2
C2
AB4
1115
AB4
855
A985 C2 B3
7 Elements
8 Elements
Hole
Self-tapping screw 14P 16
code 3540422/0
fillister head screw
Detail of pipe union with screw
Example for GN4.09
A1 = Section with flange
C2 = Intermediate section with 2 holes
B4 = End section with 4 holes
(cod. 384 )
Self-tapping screw 14Px16
code 3540422/0 fillister head screw
(cod. 384 )
Pipes
C
2
(cod. 384 )
B
3
(cod. 384 )
A
B
4
---
---
1
1
1
7 Elem.
2
1
---
1
1
8 Elem.
2
1
---
1
1
9 Elem.
1
3
---
1
2
10 Elem.
1
3
1
2
---
11 Elem.
4
---
1
1
3
12 Elem.
4
1
---
3
1
13 Elem.
5
---
4
1
1
14 Elem.
ill. 28

19
GN4
16 (fig. 30) Fit the flanged pipe "3" after inserting
the gasket "2" and the washers "4" and then
tighten with the nuts "5".
15 (fig. 29) Fit the smokebox on the four stud bolts
4, securing it with the nuts 3.
Positioning and fitting the delivery pipe with
connection to a traditional central heating sys-
tem
18 (fig. 32) Fit the diffuser pipe "1", in parts if
necessary,insertingthegasket"2"inbetween.
Ensure that the notch on the flange is facing
upwards and that the water holes are therefore
facing downwards. Fit the second gasket “2”,
the flanged pipe “3” and the washers “4” and
then tighten by means of the nuts “5”.
17 (fig.31)Fitthediffuserpipe“1”tothelowerboiler
couplinginthetraditionalversionortotheupper
boiler coupling (ill. 32) in the low temperature
version, if necessary in parts, inserting the gas-
ket “2” in between.
Ensure that the notch on the flange is facing
upwards and that the water holes are therefore
facing downwards. Fit the second gasket “2”,
the flanged pipe “3” and the washers “4” and
then tighten by means of the nuts “5”.
Positioning and fitting the diffuser pipe with
connection to a low temperature central heat-
ingsystemviatheupperboilercoupling(ill.32).
Positioning and fitting the diffuser pipe with
connection to a traditional central heating sys-
tem via the lower boiler coupling (fig. 31)
54
2
fig. 30
3
fig. 29
4
3
fig. 32
3
5
3
1
2
2
4
fig. 31
2
1
2
43
5

20 GN4
21(fig. 35) Cover the boiler
body with the sheet of
rock wool provided, fix-
ing it to the tie rods “1”
(fig. 35) by means of the
clips “7” included in the
assembly kit.
19(fig. 33) Fit the burner door, hinging it to the
supports by means of the pins “1”.20(fig. 34) Secure the door by screwing the nuts
“2” onto the stud bolts 1.
fig. 35
1
7
1
fig. 34 2 fig. 33
1