Ferroli GN4 N User manual

cod. 3544078/2 ediz. 10/2004
GN4 N
AZIENDA CERTIFICATA
ISO 9001 : 2000
high-efficiency cast iron boiler for liquid fuels and/or gas
OPERATING, INSTALLATION AND MAINTENANCE INSTRUCTIONS
caldaia di ghisa ad alto rendimento per combustibili liquidi e/o gassosi
ISTRUZIONI PER L’USO L’INSTALLAZIONE E LA MANUTENZIONE
chaudière en fonte a haut rendement pour combustibles liquides et/ou gazeux
INSTRUCTIONS POUR L’INSTALLATION ET L’ENTRETIEN
heizkessel aus gusseisen mit hohem wirkungsgrad für flüssige und/oder gasförmige brennstoffe
INSTALLATIONS-, BEDIENUNGS- UND WARTUNGSANLEITUNGEN
caldera de fundición, de alto rendimiento para combustibles líquidos y/o gaseosos
INSTRUCCIONES DE USO, INSTALACIÓN Y MANTENIMIENTO
caldeira em ferro fundido de alto rendimento para combustíveis líquidos e/ou gasosos
INSTRUÇÕES PARA O USO, INSTALAÇÃO E MANUTENÇÃO
verwarmingsketel in gietijzer met hoog rendement voor vloeibare en/of gasvormige brandstof
AANWIJZINGEN VOOR HET GEBRUIK, DE INSTALLATIE EN HET ONDERHOUD
støbejernsfyr med øget udbytte til flydende brændstof og/eller gas
INSTRUKTIONER VEDRØRENDE BRUG, INSTALLATION OG VEDLIGEHOLDELSE
sivi ve/veya gaz yakitli yüksek ver‹ml‹
DÖKÜM DÖLMLÖ KAZAN
GB
IT
FR
DE
ES
PT
NL
DK
TR

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PortuguêsNederlands
DanskTürkçe
2
GN4 N
Dear Customer,
Thank you for having chosen the GN4 N, an advanced-concept Ferroli boiler featuring cut-
ting-edge technology, high reliability and constructional quality. Carefully read this manual
and keep it for future reference.
The GN4 N is a high-efficiency heat generator for the production of hot water for heating
purposes, suitable for operation with jet burners on gas or liquid fuel.
The boiler body consists of cast-iron elements, the shape of which, together with the careful
design of the fins, ensure high heat exchange efficiency in all operating conditions.
Important warnings
• This manual provides important indications on the safety of
operation, installation and maintenance, and is an integral
and essential part of the product. Read this manual before
installation and operation. It should be carefully kept for future
reference.
• This appliance must only be used for the purposes it has been
specifically designed for. This appliance is used to heat water
to below-boiling temperatures at atmospheric pressure, and
must be connected to a heating and/or domestic hot water di-
stribution system, according to its characteristics, performance
and heating capacity. All other uses are considered improper
and thus dangerous.
• The appliance may not be opened nor its components tam-
pered with, except for the parts included in the maintenance
operations. The appliance may not be modified to alter its
performance or use.
• The installation and maintenance operations must be perfor-
med according to the standards in force, the instructions of
the manufacturer and must be carried out by professionally
qualified personnel.
• Incorrect installation or poor maintenance may cause damage
to people, animals or things. The manufacturer declines all
liability for damage deriving from errors in the installation and
operation of the appliance, and in any case from the failure to
observe the instructions provided.
• Before performing any cleaning or maintenance operations,
disconnect the appliance from the mains power supply using
the system switch and/or the corresponding on-off devices.
• In the event of faults and/or poor operation of the appliance, it
should be deactivated. Do not attempt to repair the appliance.
Contact professionally qualified personnel only.
• After having removed the packaging, check that the contents
are intact. The parts of the packaging must not be left within the
reach of children, as they are potential sources of danger.
ENGLISH
Electrical power
supply
Max operating
pressure temperature
PIN
Serial number
Max operating
pressure
Heat output
Uselful heat output
Bar code
Water content
08/250
0085AS0589
0085
230V~50Hz IP X 0D
Ser. n. 0352L50349
Q
P
-
-
kW
kW
270
250
max
160
150
min
PMS
tmax
6
100
bar
°C
PMW
D
bar
l/min
Appr. nr.
H 2 O
163 L
Certification
The CE Mark attests that Ferroli appliances
conform to the requirements specified in the
applicable European directives.
In particular, this appliance conforms to the
following EEC directives:
• Gas directive 90/396
• Efficiency directive 92/42
• Low voltage directive 73/23 (amended by 93/
68)
• Electromagnetic compatibility directive 89/336
(amended by 93/68)

3
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GN4 N
1. OPERATING INSTRUCTIONS
1.1 Control panel
21453
1.2 Ignition
Move the main switch 5to position “I” to power the boiler and the burner. Refer to the burner manual for the operation of this device.
1.3 Setting
Set the desired system temperature using the control thermostat 4. If the thermoregulation control unit (optional) is connected, refer to the
corresponding instruction manual.
1.4 Shut-down
For brief periods of inactivity, simply move switch 5(Fig. 1) on the control panel to position “0”.
For extended periods of inactivity, as well as operating switch 5, the fuel on-off valve must also be closed.
For extended periods of inactivity during the winter period, to avoid damage from frost, add special antifreeze to the system or drain the system
completely.
1.5 Anomalies
Two lockout conditions may occur that can be reset by the user:
a- Burner lockout signalled by the corresponding light 6 (Fig. 1). Refer to the burner manual.
b- Activation of the safety thermostat when the temperature in the boiler reaches the limit value above which a dangerous situation may arise.
To reset operation, unscrew cap 3and press the reset button.
If the problem occurs again, contact qualified personnel or the service centre.
In the event of faults and/or poor operation of the appliance, it should be deactivated. Do not attempt to repair the appliance. Contact profes-
sionally qualified and authorised personnel only.
2. INSTALLATION
General instructions
This appliance must only be used for the purposes it has been specifically designed for. This appliance is used to heat water to below-boiling
temperatures at atmospheric pressure, and must be connected to a heating and/or domestic hot water distribution system, according to its
characteristics, performance and heating capacity. All other uses are considered improper.
THE BOILER MUST ONLY BE INSTALLED BY QUALIFIED AND SPECIALIST PERSONNEL, IN COMPLETE COMPLIANCE WITH ALL
THE INSTRUCTIONS REPORTED IN THIS TECHNICAL MANUAL, THE LEGAL STANDARDS IN FORCE, THE PRESCRIPTIONS OF ANY
NATIONAL AND LOCAL STANDARDS, AND ACCORDING TO THE RULES OF GOOD PRACTICE.
Incorrect installation may cause damage to people, animals and things. The manufacturer will not be held liable in such events.
Place of installation
The room in which the boiler is installed must have ventilation openings to the outside according to the standards in force. If the same room
features a series of burners or exhaust devices that can operate at the same time, the ventilation openings must be large enough for the
simultaneous operation of all the appliances.
The place of installation must be free of flammable objects or materials, corrosive gas, dust or volatile substances that, sucked in by the
burner’s fan, may block the internal tubing of the burner or the combustion head. The environment must be dry and not exposed to rain, snow
or frost.
Positioning the boiler
The minimum spaces shown in the figure must be complied with. Specifically, make sure that after as-
sembling the boiler with the burner on the front door, the latter can be opened without the burner hitting
against the wall or any other boiler. Leave a free space of at least 100mm on the side that the door swings
towards.
6
100
mm
550==
Bruciatore
Key
1 Ready for electronic control unit
2 Thermometer
3 Safety thermostat
4 Control thermostat, 2 Stages
5 Line switch “0 - I - TEST”
6 Burner lockout indicator light
fig. 1
fig. 2
Burner

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4
GN4 N
2.1 Water connections
Make the water connections to the appliance according to the indications shown both next to each fitting and in Figure 2 of this booklet.
The connections must be made in such a way that the pipes are not under stress. The safety valve must be fitted in the central heating circuit,
as close as possible to the boiler, without there being any obstructions or on-off devices between the boiler and the valve.
The appliance is not supplied with an expansion vessel, and therefore such device must be connected by the installer. Please note that in this
regard, the pressure in the system, when cold, must be between 0.5 and 1 bar.
2.2 Connecting the burner
Oil or gas jet burners for pressurised furnaces can be used if their operating characteristics are suitable for the dimensions of the boiler’s
furnace and its over-pressure value. The burner must be chosen following the instructions provided by the manufacturer, according to the
field of operation, fuel consumption and pressure, as well as the length of the combustion chamber.
Fit the burner following the instructions provided by the manufacturer of the device.
2.3 Electrical connections
The boiler should be connected to a single-phase, 230 Volt-50 Hz electrical line, using a permanent connection, installing a double
pole switch with contact openings of at least 3mm, and suitable fuses. Connect the burner and the room thermostat (if featured) as
shown in the wiring diagram in Chap. 4.
The electrical safety of the appliance is ensured only when the appliance is correctly connected to an effective earth system, as pre-
scribed by the safety standards in force. Have professionally qualified personnel check the efficiency and the rating of the earth system. The
manufacturer is not liable for any damage caused by the appliance not being correctly earthed. In addition, make sure that the electrical system
is adequately rated for the maximum power absorbed by the appliance, indicated on the rating plate, and in particular that the cross-section
of the wires is suitable for the power absorbed by the appliance.
2.4 Flue connections
The boiler should be connected to a suitable flue, manufactured in compliance with the standards in force. The pipe between boiler and the flue
must be made from material suitable for this purpose, that is, resistant to both high temperatures and corrosion. The joints should be carefully
sealed and the entire length of the pipe between the boiler and the flue should be thermally insulated, to avoid the formation of condensate.
2.5 Assembling the boiler
The boiler may be supplied:
1. As a set of elements, in 4 separate boxes, containing the Casing, Control panel, Elements, and accessories for assembling the elements.
Follow the instructions enclosed with the set of elements to assemble the boiler body. Follow the instructions below to assemble the casing
and control panel.
2. With the body already assembled, in 3 separate boxes containing the Casing, Control panel and Boiler body.
Follow the instructions below to assemble the casing and the control panel.
AIf the boiler body
is supplied already
assembled and is
delivered from the
factory on a pallet,
remove the bolts 1
that fasten it to the
pallet and position it
for final installation.
Then assemble the
various panels.
CPrepare the right and left sides, choosing the quantity of side panels according to
the dimensions of the boiler (see table).
AB
C
1
1
22
22
7 elem.
9÷12 elem.
13÷14 elem.
14 elem. F. a. DX + SX +
C. a. F. 2 + C. 2 F. 2 + C. 2 F. 2 + C. 2
13 elem. F. a. DX + SX +
C. a. F. 1 + C. 1 F. 2 + C. 2 F. 2 + C. 2
12 elem. F. a. DX + SX +
C. a. F. 3 + C. 3 F. 3 + C. 3
11 elem. F. a. DX + SX +
C. a. F. 2 + C. 2 F. 3 + C. 3
Side panels
F. a. DX = 330 mm (cod. 3703812/0)
F. a. SX = 330 mm (cod. 3703813/0)
F. 1 = 406 mm (cod. 3703814/0)
F. 2 = 536 mm (cod. 3703815/0)
F. 3 = 666 mm (cod. 3703816/0)
Cover
C. a. = 273 mm (cod. 3703822/0)
C. 1 = 406 mm (cod. 3703819/0)
C. 2 = 536 mm (cod. 3703820/0)
C. 3 = 666 mm (cod. 3703821/0)
10 elem. F. a. DX + SX +
C. a. F. 2 + C. 2 F. 2 + C. 2
9 elem. F. a. DX + SX +
C. a. F. 2 + C. 2 F. 1 + C. 1
8 elem. F. a. DX + SX +
C. a. F. 1 + C. 1 F. 1 + C. 1
7 elem. F. a. DX + SX +
C. a. F. 3 + C. 3
1
BFit the rear panel 1on
the studs 2and loosely
tighten the bolts.

5
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GN4 N
DConnect the panels together, using the screws 1, the washers 2 and the nuts 3,
reinforcing the bottom parts using the blades 4 fastened with the screws 5.
ELoosen the nuts “A”. Insert the side fastening bracket “B”
FFasten the sides to the rear wall “A” using the screws “B”.
GFit the side to the bracket “A” and fasten it using the screws “B” (right
side view). Repeat the operations in point G for the left side.
HFasten the sides to the rear wall “A” using the screws “B”.
IFit the wiring protection case “A” using the screws “B” on the sides.
LFit the control panel to the sides using the tabs “A”. Place
the reinforcement spring “B” between the head of the screw
and the tab.
OFit the upper panel “A”.
PFit the top cover or covers “A”, according to the length of the boiler (see table 1, sequence
C).
E
F
B
A
B
A
B
B
GH
I
A
B
B
AB
BB
A
L
MN
B
A
A
P
A
O
A
M Insert the 3 bulbs (safety thermostat, boiler thermostat and
thermometer).
N Fit the lower front panel “A”.

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GN4 N
3. SERVICE AND MAINTENANCE
All the adjustment, commissioning and maintenance operations must be performed by Qualified Personnel, in compliance with the standards
in force.
FERROLI S.p.A. declines all liability for damage to persons and/or things deriving from the tampering with the appliance by unqualified or
unauthorised persons.
Before performing any cleaning or maintenance operations, disconnect the appliance from the mains power supply using the system switch
and/or the special on-off devices.
3.1 Commissioning
Checks to be performed on first ignition, and after all maintenance operations that involve the disconnection of the appliance from the systems
or intervention on the safety devices or parts of the boiler:
Before first ignition
Before igniting the boiler for the first time, check that:
athe system is filled at the right pressure and any air has been correctly vented;
bthere are no water or fuel leaks;
cthe electrical power supply is correct;
dall the flues have been installed correctly and not too near to or across any flammable parts;
ethere are no flammable substances near the appliance;
fthe burner is suitably sized for the output of boiler;
gthe water on-off valves are open.
First ignition
After having carried out the preliminary checks, the following ignition operations can be performed:
1Open the fuel on-off valve.
2Set the thermostat 4 (Fig. 1) to the desired value.
3Close the switch upstream from the boiler and switch 5 (Fig. 1) on the control panel.
At this stage, the burner will be ignited and the boiler will start operation.
After first ignition
After first ignition, check that:
1The door of the burner and smokebox are well sealed.
2The burner is working correctly. This check should be performed using the required instruments, following the manufacturer’s instruc-
tions.
3The thermostats are working correctly.
4Water is circulating in the system.
5The flue gas is completely expelled through the flue.
3.2 Adjustments
Adjusting the burner
The efficiency and correct operation of the boiler depend above all on accuracy of the adjustments made to the burner.
Carefully follow the instructions provided by the manufacturer. Two-stage burners must have the first stage adjusted to an output that is no
lower than the minimum rated output of the boiler. The output of the second stage must not be greater than the maximum rated output of the
boiler.
3.3 Shut-down
For brief periods of inactivity, simply use switch 5 (Fig. 1) on the control panel.
For extended periods of inactivity, as well as operating switch 5, the fuel on-off valve must also be closed.
3.4 Maintenance
To ensure the maximum reliability of the heating system and minimum running costs, the boiler must be cleaned regularly, at least once a year.
These maintenance operations must be performed by qualified and specialist personnel.
Cleaning the boiler
1Disconnect the power supply to the boiler
2Remove the upper and lower front panel.
3Open the door by unscrewing the knobs.
4Clean the inside of the boiler and the entire flue gas discharge path, using a brush or compressed air.
5Close the door again, and fasten it using the knob.
To clean the burner, refer to the instructions provided by the manufacturer.

7
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GN4 N
4. TECHNICAL SPECIFICATIONS
Water
pressure
drop
Modello
Heat
output
kW
GN4 N 07
GN4 N 08
GN4 N 09
GN4 N 10
GN4 N 11
GN4 N 12
GN4 N 13
GN4 N 14
Max
217
270
324
388
452
516
600
695
Heat input
gas+oil
(NHV) kW
Max
200
250
300
360
420
480
560
650
Min
120
150
180
215
250
290
330
390
N°
elem.
7
8
9
10
11
12
13
14
Water
content
dm3
143
163
183
203
223
243
263
283
Operating
pressure
bar
6
6
6
6
6
6
6
6
A
mm
1040
1170
1300
1430
1560
1690
1820
1950
B
Ø
mm
210
210
210
210
210
210
210
210
C
Ø
mm
180
180
250
250
250
250
250
250
D
Ø
mm
500
500
500
500
500
500
500
500
880
1010
1140
1270
1400
1530
1660
1790
E
mm
Comb.
chamber
pressure
drop
∆p mbar
0,5
0,8
0,7
1,0
1,4
1,7
2,6
3,5
Comb.
chamber
volume
dm3
161,3
185,1
208,9
232,8
256,6
280,4
304,3
328,1
∆t 20
20
30
42
54
65
77
88
100
∆t 10
-
-
-
-
-
-
-
-
Body
weight
kg
840
950
1060
1170
1280
1390
1500
1610
Min
128
160
192
229
266
309
352
416
140
40
0
0 5 10 15 20 25 30 35
m
3
/h
20 40 60 80
100 120
mbar
fig. 3
fig. 4
fig. 5
GN4 N 7-8-9
GN4 N 10-11-12-13-14
898
38083
10
A138
0
850
1193
463
B
C
D
E
A1B2B1
A2
Legenda
A1 Central heating flow outlet DN80 - 3”
A2 Central heating return inlet DN80 - 3”
B1 Central heating flow outlet DN80 - 3”
(Low temperature)
B2 Central heating return inlet DN80 - 3”
(Low temperature)
32 Pump (not supplied)
49 Safety thermostat
72 Room thermostat (not supplied)
98 Switch
114 Water pressure Switch
159 Test knob
170 Boiler setting thermostat, 1st stage
171 Boiler setting thermostat, 2nd stage
189 Lockout indicator light (not supplied)
211 Burner connector
Note The dashed sections of wiring are the respon-
sibility of the installer

37047 SAN BONIFACIO - VR - ITALY
tel. [phone] - tlx 480172
fax [phone]
www.ferroli.it