Ferroli GN4 N User manual

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
cod. 35440785 - 12/2006 (Rev. 00)
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2
GN4 N
Cod. 35440785 - 12/2006 (Rev. 00)
Dear Customer,
Thank you for having chosen the GN4 N, an advanced-concept Ferroli boiler
featuring cutting-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 distribution
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
tampered 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
performed 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 opera-
tions, disconnect the appliance from the mains power
supply using the system switch and/or the correspon-
ding 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
Cod. 35440785 - 12/2006 (Rev. 00)
1. OPERATING INSTRUCTIONS
1.1 Control panel
21 4 53
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 con-
nected, 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 professionally 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 COM-
PLIANCE 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 assembling 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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GN4 N
Cod. 35440785 - 12/2006 (Rev. 00)
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 prescribed 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 cor-
rectly 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 sup-
plied already assembled
and is delivered from
the factory on a pallet,
remove the bolts 1that
fasten it to the pallet and
position it for final instal-
lation. 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
1
1
22
2
2
1
C
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
BFit the rear panel 1on
the studs 2and loosely
tighten the bolts.

5
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GN4 N
Cod. 35440785 - 12/2006 (Rev. 00)
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
M N
B
A
A
P
A
OA
MInsert the 3 bulbs (safety thermostat, boiler thermostat and
thermometer).
NFit the lower front panel “A”.

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GN4 N
Cod. 35440785 - 12/2006 (Rev. 00)
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 manufac-
turer’s instructions.
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
Cod. 35440785 - 12/2006 (Rev. 00)
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
fig. 3
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
211 Burner connector
Note The dashed sections of wiring are the responsibility
of the installer
fig. 4