Ferroli GN4N User manual

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GN4 N
HIGH-EFFICIENCY CAST IRON BOILER FOR LIQUID FU-
ELS and/or GAS
OPERATING, INSTALLATION AND MAINTENANCE IN-
STRUCTIONS
CALDAIA DI GHISAAD ALTO RENDIMENTO PER
COMBUSTIBILI LIQUIDI E/O GASSOSI
ISTRUZIONI PER L’USO L’INSTALLAZZIONE E LA
MANUTENZIONE
CHAUDIÈRE en FONTE A HAUT RENDEMENT POUR
COMBUSTIBLES LIQUIDES et/ou GAZEUX
INSTRUCTIONS POUR L’INSTALLATION ET L’ENTRETIEN
HEIZKESSELAUS GUSSEISEN MIT HOHEM WIRKUNGS-
GRAD FÜR FLÜSSIGE und/oder GASFÖRMIGE BRENN-
STOFFE
INSTALLATIONS-, BEDIENUNGS- UND WARTUNGSAN-
LEITUNGEN
CALDERA DE FUNDICIÓN, DE ALTO RENDIMIENTO PARA
COMBUSTIBLES LÍQUIDOS y/o GASEOSOS
INSTRUCCIONES DE USO, INSTALACIÓN Y MANTENI-
MIENTO
CALDEIRA em FERRO FUNDIDO DE ALTO RENDIMENTO
PARA COMBUSTÍVEIS LÍQUIDOS e/ou GASOSOS
INSTRUÇÕES PARA O USO, INSTALAÇÃO E MANUTEN-
ÇÃO
VERWARMINGSKETEL in GIETIJZER MET HOOG RENDE-
MENT VOOR VLOEIBARE en/of GASVORMIGE BRAND-
STOF
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 VERSIVI VE/VEYA GAZ YAKITLI YÜKSEK VER
SIVI VE/VEYA GAZ YAKITLI YÜKSEK VERSIVI VE/VEYA GAZ YAKITLI YÜKSEK VER
SIVI VE/VEYA GAZ YAKITLI YÜKSEK VER‹MLML
MLML
ML‹DÖKÜMDÖKÜM
DÖKÜMDÖKÜM
DÖKÜM
DD
DD
D‹LL
LL
L‹MLML
MLML
ML‹KAZANKAZAN
KAZANKAZAN
KAZAN
ENGLISH
ITALIANO
FRANÇAIS
DEUTSCH
ESPAÑOL
PORTUGUÊS
NEDERLANDS
DANSK
TÜRKÇE
cod. 3544078/0 ediz. 02/2002

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GN4N
Dear Customer,
Thank you for having chosen the GN4 N, an advanced-concept Ferroli boiler
featuringcutting-edgetechnology, highreliabilityandconstructionalquality.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
• Thismanualprovides importantindicationsonthesafety
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,
accordingtoits characteristics, performanceandheating
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
damageto people,animalsor things.Themanufacturer
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
C97.02G 07
CE-0085AS0589
0085
1QGDX05B
028693 3301698
EN303 - Appr.No.
PIN
Type
N°
GN4 N 07
0000000000
MAX. MIN.
217 128
200 120
kW
kW
Q (Hi)-INPUT
P -OUTPUT
PMS 4 bar - Tmax 110 °C- - H2O 143 I
230 V - ~50 Hz
IPX0D
Electrical power
supply
Max operating pressure
temperature
Manufacturer PIN
Trade name
Serial number
Max operating
pressure
Heat output
Uselful heat output
Bar code
Water content
Ferroli Spa
Via Ritonda 78A 37047 San Bonifacio (VR) - Italia
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)

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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.
Forextendedperiodsof inactivityduringthewinter period,toavoiddamage fromfrost,addspecial antifreezetothesystem ordrainthesystem
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.
Intheeventoffaultsand/orpooroperationoftheappliance,itshouldbedeactivated.Donotattempttorepairtheappliance.Contactprofessionally
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.
THEBOILERMUSTONLY BE INSTALLEDBY QUALIFIED ANDSPECIALISTPERSONNEL,INCOMPLETECOMPLIANCEWITHALL 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
hittingagainst the wallor any other boiler.Leavea free space of at least 100mmon the sidethat the door
swings towards.
6
100
mm
550==
Bruciatore
Key
1Ready for electronic control unit
2Thermometer
3Safety thermostat
4Control thermostat, 2 Stages
5Line switch “0 - I - TEST”
6Burner lockout indicator light
fig. 1
fig. 2
Burner

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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
furnaceand itsover-pressurevalue.The burner mustbe chosenfollowing the instructionsprovided bythe manufacturer,accordingto thefield
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
thesafety standards in force.Have professionallyqualified personnel check the efficiencyand the ratingof the earth system.The manufacturer
isnot liable for any damage caused by the appliance not being correctly earthed.In addition, make sure that the electrical systemis 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
Theboiler shouldbe connected toa suitableflue, manufacturedin compliance with the standardsin force.Thepipe between boilerand the flue
mustbe made frommaterial suitable for this purpose, that is,resistant to bothhigh temperatures and corrosion. The joints shouldbe 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.
Followthe 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 elementi
9÷12 elementi
13÷14 elementi
14 elem.
F. ant. DX e SX +
cop. ant. F. 2 + Cop. 2 F. 2 + Cop. 2 F. 2 + Cop. 2
13 elem.
F. ant. DX e SX +
cop. ant. F. 1 + Cop. 1 F. 2 + Cop. 2 F. 2 + Cop. 2
12 elem.
F. ant. DX e SX +
cop. ant. F. 3 + Cop. 3 F. 3 + Cop. 3
11 elem.
F. ant. DX e SX +
cop. ant. F. 2 + Cop. 2 F. 3 + Cop. 3
Fianchi
F. ant. DX = 330 mm (cod. 3703812/0)
F. ant. 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)
Coperchi
Cop. ant. = 273 mm (cod. 3703822/0)
Cop. 1 = 406 mm (cod. 3703819/0)
Cop. 2 = 536 mm (cod. 3703820/0)
Cop. 3 = 666 mm (cod. 3703821/0)
10 elem.
F. ant. DX e SX +
cop. ant. F. 2 + Cop. 2 F. 2 + Cop. 2
9 elem.
F. ant. DX e SX +
cop. ant. F. 2 + Cop. 2 F. 1 + Cop. 1
8 elem.
F. ant. DX e SX +
cop. ant. F. 1 + Cop. 1 F. 1 + Cop. 1
7 elem.
F. ant. DX e SX +
cop. ant. F. 3 + Cop. 3
1
BFit the rear panel 1on the
studs 2and loosely
tighten the bolts.

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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”.
GFitthesidetothebracket“A”andfastenitusingthescrews“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
thereinforcementspring“B”betweentheheadofthescrew
and the tab.
OFit the upper panel “A”.
PFitthetopcoverorcovers“A”,accordingtothelengthoftheboiler(seetable1,sequenceC).
E
F
B
A
BA
B
B
GH
I
A
B
B
AB
BB
A
L
MN
B
A
A
P
A
O
A
MInsert the 3 bulbs (safety thermostat, boiler thermostat and
thermometer).
NFit the lower front panel “A”.

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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
Checksto be performed onfirst ignition, andafter all maintenance operations that involve the disconnectionof the appliancefrom thesystems
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.
2Theburner isworking correctly.This checkshould beperformedusing the requiredinstruments, followingthe manufacturer’sinstructions.
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 ensurethe maximumreliability ofthe heating system and minimumrunning costs,the boilermust be cleanedregularly,at leastonce 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.

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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
4
4
4
4
4
4
4
4
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
00 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 6-7-8
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
responsibility of the installer