Ferroli GNK1 Series Operating and maintenance manual

GNK1
CAST IRON SECTIONAL BOILER
FOR HEATING AND PRODUCTION
DOMESTIC HOT WATER
INSTALLATION AND
USE INSTRUCTIONS

2

3
INDEX
1. Technical informations
2. Dimensions and technical data
3. Packing and shipping details
4. Installation
5. Checking
6. Service
7. Optional
8. Boiler components

4
Fig. 1
1
543
7
26
Legende:
1Manothermomètre chaudière
2Thermomètre ballon
3Aquastat réglage chaudière
4Aquastat réglage sanitaire
5Interrupteur été/hiver
6Aquastat de sécurité
7Emplacement pour horloge (facultatif)
1.02 Operative principle
Summer/Winter switch on the «WINTER» setting.
When the switch has been set to the «Winter» position, the appliance is able to produce hot water for
sanitary and heating purposes, with priority to the sanitary circuit. The burner will ignite, the plant
circulator will remain at a standstill while that of the heater will allow water to circulate between the
boiler and the heater itself. Once the water in the heater reaches the temperature value preset by the
thermostat of this latter, the heater circulator stops and that of the heating system will start operating.
When the room temperature has reached the value set on the ambient thermostat, the burner and
circulator stop until heat is again required by the heating system or heater.
If the heater becomes cooled during the heating phase following use of sanitary water, the plant
circulator will immediately stop and thet of the heater will start operating until the temperature set on
the thermostat of this latter has been reached.
1. TECHNICAL INFORMATIONS
1.01 Introduction
GNK1 boiler is a new heating generator with high efficiency, for central heating system as well sanitary
hot water production suitable for burners using oil or gas. The boiler body is built by cast iron sections
joined togheter by mean of biconical nipples and tie rods. Sections fins are especially developped to
achieve the best efficiency fuel consumption. The heater is the quick accumulating type made of
vitreous enamelled steel, able to withstand the onset of rust for a very long time. The boiler body
insulation is provided by mineral high density fibers that minimizes the body heat lost.

5
Summer /Winter switch on the «SUMMER» setting
When the switch has been set to this position, the plant will produce hot sanitary water only and the
relative heating circuit will be kept permanently off. The burner and circulator will therefore only
operatetomaintainthetemperatureofthesanitarywaterwhilstthisisbeingusedorduringlongperiods
at a standstill.
1.03 Control and securities devices operation
Regulating thermostat, manual resetting
It operates when the boiler temperature, during the heating mode reach for sanitary hot water
productionsuchalevelthatcanusea danger situation. Before resettingthisthermostat ask for Qualified
Serviceman to inspect the appliance.
Central thermostat
Itallowstocontroltheboilertemperaturebymeanofitsknobs.Thisthermostatonlycontrolstheburner
during the heating phase.
Room thermostat (not supplied)
This device is not supplied, but can be fitted by installer, it is connected in series to the control
thermostat and it manages both the burner and the circulating pump during the heating mode.
Heater regulating thermostat
Regulates the temperature of the sanitary water.
Controls the burner and heater circulator at the same time, after having by-passed the boiler regulating
thermostat and ambient thermostat if installed.
It therefore has priority over the other two thermostats.
Limit thermostat
Acts as a boiler regulating thermostat with fixed setting when hot sanitary water is produced, i.e. when
the boiler thermostat is by-passed by the heater thermostat. This thermostat can therefore meet two
often opposed requirements:
a) boiler temperature regulation during the heating phase;
b) the highest possible temperature in the boiler during the hot sanitary water production phase.

6
123 654
7
1370
105
715
a2
252 422 1013
500
130
a4
a5
a6
a3
82
10
8
631
551
a1
9
745
Fig. 2
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)saG(
niM
Wk
.xaM
Wk
.niM
Wk
.xaM
Wk
.niM
Wk
.xaM
Wk
201KNG 20,513,324,618,522,816,82
301KNG30,514,134,618,432,816,83
401KNG45,235,644,536,153,933,75
ledoM
gnitaeHlartneC
retawxam
erusserp
gnitaeHlartneC
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retawrelioB
tnetnoc
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erusserpretaw
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tnetnoc
wolf.W.H.D
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rab°Cmd
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rabmd
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.nim01/lh/l
201KNG 40110,11909071037
301KNG 40110,41909002058
401KNG 40110,71909002058
Tabelle
2. DIMENSIONS AND TECHNICAL DATA
2.01 Dimensions and technical data (fig. 2 - tables 1)
Key
1Thermomanometer boiler
2Thermometer boiler
3Timer sochet
4Boiler thermostat control
5Boiler thermostat control
6Switch Summer/Winter
7Security thermostat
8Circulating pump boiler
9Valve automatic
10 Non-return valve
a1 Flow 1" 1/2
a2 Return 1"
a3 Boiler drain 1/2"
a4 Hot sanitary water outlet
a5 Recirculation
a6 Cold sanitary water inlet

7
Fig. 3
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noitsubmoC
thgnelrebmahc
noitsubmoC
rebmahc
snoisnemid
tsiseredisekomS
mmmm∆rabmp
201KNG 682013x0622,0
301KNG683013x0622,0
401KNG684013x0622,0
N.B.: Max. water temperature for the heating system is 110°C.
NOTE: When priority ends with high temperature water in the boiler, the thermal inertia which
develops when the circulator stops could inhibit the boiler itself (total switch-off) owing to
activation of the safety thermostat at 100˚C. To prevent this inconvenience, the plant has been
equipped with a heater thermostat called circulator thermostat (TC). When the boiler
temperature exceeds the value preset by this thermostat, the heater circulator is actived until
the temperature drops below that value.
2.02 Pressure drop (fig. 3)
Pressure drops according to the boiler size are specified on the following diagram and refer to
temperature difference between flow and return comprises between 10 and 20°C.

8
Fig. 4
KEY
1Automatic air vent
2Safety valve
3Cock drain
4Coil
5Boiler
6Safety thermostat boiler
7Anode
8Heating plant expansion tank (not supplied)
9Circulating pump thermostat
10 Sanitary plant expansion tank (not supplied)
11 Boiler thermostat
12 Safety thermostat
13 Thermometer boiler
14 Thermometer boiler
15 Safety thermostat
16 Circulating pump thermostat
17 Boiler shell
18 Burner
19 Cock drain boiler
20 Water gauge
21 Circulating pump boiler
22 Safety valve (not supplied)
23 Non-return valve
2.03 Hydraulic diagram
Flow
Return
Hot sanitary
water outlet
Recirculation
Cold sanitary
water inlet

9
Fig. 5
4. INSTALLATION
It is law that all gas appliances are installed by Competent Persons, in accordance with the
regulations. Failure to install appliances correctly lead to prosecution, it is in your own interest, and
that of safety, to ensure that the law is coplied with. Manufacturers instructions must NOT
be taken in any way as over-riding statutory obligations, special care must be paid to conform
with law and regulation concerning building and location of the chimney.
4.01 Electrical connection
Proceed to wire pump, burner and optional room thermostat. According to the wiring diagrams
(fig. 19) and to the directions attached to the cables. It is recommended to install a two-pole switch
between the power supply and the boiler. The switch contacts must have a clearance of at least 3 mm
and fuses of 5 A max must be provided.
N.B. - Appliance must be earthed.
It is recommended to connect the boiler to a good electric earth system. FERROLI could not
be considered responsable for any kind of damage to Persons or things caused by failure of earthing
the system.

10
230V
50 Hz
RL
RL
TC
1
14
b
EI
CR
1
36
35
34
C
15
N
L
CB
17
RL
13
12
11
TRB
19
a
2
3
1
2
20
FU
18
21
24 10
9
5
22
TA
OP
23
25
16 26
2
1
B
3
4
5
8
74
TS
TRC
31
3032
29
TLB
28
27
6
6
38
e
7
EI
M
24
37
= REMOVE THE LINK WHEN TA IS INSTALLED
4.02 Connection to the water main
Connect the appliance to the water main in compliance with the indications near each fitting and those
listed in fig. 2 of this handbook. Connections must be made so that the pipes are free from tensions.
It is essential to mount the safety valve on the heating circuit and on the sanitary circuit, using the
relative fittings in the boiler. Valve settings must be 3 bar for the heating circuit and 6 bar for the sanitary
circuit. It is advisable to mount manual on-off valves between the boiler and the two heating and
sanitary systems in order to isolate the boiler from the two systems when necessary.
NOTE: The boiler is supplied without expansion tank.
Installation of this latter therefore be at the user’s charge. Remember that the pressure in the system
when cold must be between 0,5 and 1 bar.
TRC = THERMOSTAT CONTROL BOILER
TC = THERMOSTAT CIRCULATING PUMP
CR = CIRCULATING
TS = SAFETY THERMOSTAT
B=BURNER
OP = PROGRAMMER CLOCK (OPTIONAL)
S=DIAGRAM
TRB = THERMOSTAT BOILER
CB = CIRCULATING PUMP
TA = ROOM THERMOSTAT (NOT SUPPLIED)
EI = SUMMER-OFFWINTER SELECTOR
FU = FUSIBLE 5A
TLB = BOILER LIMIT THERMOSTAT
ELECTRIC DIAGRAM

11
M
2
35
8
6
5
1
35
34
37
36
OP
34
19
25
18
24
TRC
TRB
7
C
3
13
12
15
11
b
2
FU
38
CB
TC
EI
N
L
230V 50 Hz
TA
10
9
8
7
6
5
4
2
1
3
20
TS
2
14 17
31
4
16
1
21 22 23
S
30
28
26
TLB
1
B
27
32
29
1
CR
5
d e
C
a
1
2
4.03 Connection to the chimney
It is recommended to connect the boiler to a good working chimney built according to the regulations.
The connection between boiler and chimney must be done by using suitable material proof against
high temperature and corrosion. Its length must be as short as possible, with the least number of curves.
Where flue sections have to be connected it is advised pay attention to avoid leaking and provided
good insulation through all the flue length to avoid condensing problem.
= REMOVE THE LINK WHEN TA IS INSTALLED
TRC = THERMOSTAT CONTROL BOILER
TC = THERMOSTAT CIRCULATING PUMP
CR = CIRCULATING
TS = SAFETY THERMOSTAT
B=BURNER
OP = PROGRAMMER CLOCK (OPTIONAL)
S=DIAGRAM
TRB = THERMOSTAT BOILER
CB = CIRCULATING PUMP
TA = ROOM THERMOSTAT (NOT SUPPLIED)
EI = SUMMER-OFFWINTER SELECTOR
FU = FUSIBLE 5A
TLB = BOILER LIMIT THERMOSTAT
ELECTRIC DIAGRAM

12
5. TESTING
5.01 Before the first light of the boiler
Before the first light of the boiler follow these check list:
a) check the system and the boiler is filled with water at the right pressure;
b) check against any leakage of water fuel;
c) check that the correct electric power is supplied to the unit;
d) check size and perfect flue installation. Flue must not be placed near flammable materials;
e) check against any type of flammable materials where the boiler is installed;
f) check the burner has the right heat input according to the boiler size;
g) control that the water valves are open.
5.02 First lighting
After the boiler preliminaires checking, the appliance can be lights in the following way:
1) Open the fuel gate valve.
2) Set the «Summer/Winter» switch to one of the two settings.
3) Regulate the boiler and heater thermostats to the required values.
4) Shut the switch upstream of the boiler together with that on the control panel.
After above operations the burner will start to run and the boiler will begin to work.
5.03 After the first lighting
After the first lighting it is advisable check:
Burner works properly, this checking must be done by appropriate instruments.
Thermostats operate correctly.
Water flows through the system and in the boiler.
Smoke gases evacuate through the flue duct.
5.04 Switch off
To turn off the unit for a short period it is enough to switch off the switch on the control panel.
If the boiler has to be stopped for long period beside to act by the switch on the control panel, it is
necessary to cut the supply of fuel by mean of the gate valve, in winter season, to avoit damages due
to the frost it is necessary to add the antifrost liquid in the system and to drain the boiler.
6. SERVICE
The after sale service must be carried out only by Qualified Plumbers. It is advise to service the boiler
at least once a year, before the winter season. Checks must include the boiler cleaning, the perfect
operation of the controls and the burner.
Furthermore the flue duct conditions have to be inspected.
The frequency with which the protecting anode of the heater should be inspected will be established
by the agressivity of the mains water. The interval between one inspection and the next should not
exceed 2 years.

13
Fig. 7
6.01 Boiler cleaning
Cut out electric power.
Cut out the panec 1, 2 and 3 (fig. 7).
Clean the boiler internal parts.
Check the flue duct and if necessary clean it.
The burner service must be done according the Manufacture Instructions.
6.02 Boiler cleaning
Shut the sanitary water on-off valve at the heater inlet and completely drain the water from the heater
itself.
Remove the flange from the front side of the heater. Wash and dry the heater.
Replace the heater flange and front panel of the casing, then re-open the sanitary water on-off valve.
NOTE: Only use specific productes available on the market when washing the heater. Never use hard
or metal tools to remove the scaling.
Cleaning brush
Anode

14
Fig. 8
7. OPTIONALS
7.01Programmer clock
1-Remove plug «A» from the control panel.
2-Fit clock «B» into its housing.
3-Fix with screws «C».
4-Remove the jumper between terminals 11-12 and connect the clock cables as shown in the wiring
diagram.

15
7.03 Technical specifications
Unipolar switch or commutator, 16A/250V switch - m contact. Quarz controlled stepping motor.
Mains voltage 230V - 50/60 Hz. Rated power 1,7 Watt (6,5 mA). Room temperature from - 10°C to
+ 55°C. Program disk with 96 mobile rods. 15 minute activation time. 150 hour charge reserve.
7.02 Programming
Turn the program disk in a clockwise direction to set the time just like a normal clock.
Lower the mobile rods to select the activation times can be at a frequency of 15 minutes a time (each
mobile rod).
The lever switch near the pointers enables the following operations:
1- Set the lever to position «I» ti inhibit heater boiler operation.
2- Set the lever to position «0» and the boiler will operate continuously for heating, controlled by both
the boiler and roon thermostats.
3- Set the lever between positions «I» and «0» and the boiler will operate automatically for heating,
according to the program set by the User with the mobile rods.
program disk with
mobile rod
activation point indication
on
off
220V - 50/60 Hz
connection
terminal
16A - 250V
switch
Fig. 9

16
Fig. 10
8. BOILER COMPONENTS

17
POS. COD. DESCRIPTION
1 33004700 FRONT SECTION
2 33004710 REAR SECTION
3 33004720 MIDDLE SECTION
4 33100600 REDUCTION COLLAR
5 31208180 ANGLE DX
6 31208190 ANGLE SX
7 33202120 UPPER DOOR
8 33202100 SPY HOLE COVER
9 33202280 BURNER DOOR
10 33400700 PROBES POCKET
11 33600340 REDUCTION
12 34000600 REDUCTION 1" - 1/2"
13 34000610 PLUG
14 34008750 NIPPLE
15 34008800 1"1/2 PUMP FITTING OT58
16 34010220 FIXED BRACKET EXTENSION
17 34204000 BICONAL NIPPLE
18a 34223660 TUBE
18b 34223670 TUBE
18c 34223680 TUBE
19a 34400010 TIE ROD
19b 34400910 TIE ROD
19c 34403010 TIE ROD
20 34502060 SPRING
21 34505170 BAR
22 35316340 INSULATION PANEL
23 35316550 INSULATION PANEL
24 36600730 PUMP
26 36900660 VALVE
27 36900700 COCK
28 36900880 VALVE
29 36901140 NO RETURN VALVE
30 36901210 NO RETURN VALVE
31 37704480 UNIT COMPLETE
32 38443130 PIPE
33 38443110 PIPE
34 38443120 PIPE
36a 38443170 PIPE
36b 38443180 PIPE
36c 38443190 PIPE
37 31206800 SIDE

18
Fig. 11
61
62

19
POS. COD. DESCRIPTION
40 37026530 RIGHT SIDE PANEL
41 37026540 LEFT SIDE PANEL
42 37026550 COVER
43 37026560 UPPER FRONT PANEL
44 37026570 LOW FRONT PANEL
45 38505621 COMPLETE CONTROL PANEL
46 38315370 CARD ELECTRIC
47a 31133680 REAR PANEL
47b 31133690 REAR PANEL
47c 31133700 REAR PANEL
48 31000210 SPRING
49 35000640 TUBE BRUSH
50 35001820 PLUG
51 35002520 KNOB
52 35003130 FACIA PANEL
53 36100340 SWITCH
54 36400790 THERMOSTAT
55 36401450 THERMOSTAT
56 36401190 THERMOSTAT
57 36401230 THERMOSTAT
58 36401260 THERMOSTAT
59 36401740 THERMOMETER
60 31137460 UPPER REAR PANEL
61 32911830 WIRING BOX COVER
62 32911830 WIRING BOX

37047 San Bonifacio - VR - Italia
tel. [phone] • tlx. 480172
fax [phone]
Cod. 3540573/0 07/97