Ferroli PREXTHERM N 107 User manual

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PREXTHERM N
HIGH-EFFICIENCY STEEL BOILER FOR LIQUID FUELS
AND/OR GAS
OPERATING, INSTALLATION AND MAINTENANCE IN-
STRUCTIONS
CALDAIA IN ACCIAIO AD ALTO RENDIMENTO PER
COMBUSTIBILI LIQUIDI E/O GASSOSI
ISTRUZIONI PER L’USO L’INSTALLAZIONE E LA
MANUTENZIONE
CHAUDIÈRE EN ACIER 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 ACERO, DE ALTO RENDIMIENTO PARA
COMBUSTIBLES LÍQUIDOS Y/O GASEOSOS
INSTRUCCIONES DE USO, INSTALACIÓN Y MANTENI-
MIENTO
CALDEIRA DE AÇO DE ALTO RENDIMENTO PARA COM-
BUSTÍVEIS LÍQUIDOS E/OU GASOSOS
INSTRUÇÕES PARA O USO, INSTALAÇÃO E MANUTEN-
ÇÃO
VERWARMINGSKETEL MET HOOG RENDEMENT VOOR
VLOEIBARE en/of GASVORMIGE BRANDSTOF
AANWIJZINGEN VOOR HET GEBRUIK, DE INSTALLATIE
EN HET ONDERHOUD
STØBEJERNSFYR UDBYTTE TIL FLYDENDE BRÆND-
STOF OG/ELLER GAS
INSTRUKTIONER VEDRØRENDE BRUG, INSTALLATION
OG VEDLIGEHOLDELSE
S›v› ve / veya gazl› yak›tlar için yüksek verimli çelik kazan
Montaj, kullan›m ve bak›m k›lavuzuMontaj, kullan›m ve bak›m k›lavuzu
Montaj, kullan›m ve bak›m k›lavuzuMontaj, kullan›m ve bak›m k›lavuzu
Montaj, kullan›m ve bak›m k›lavuzu
ENGLISH
ITALIANO
FRANÇAIS
DEUTSCH
ESPAÑOL
PORTUGUÊS
NEDERLANDS
DANSK
TÜRKÇE
cod. 3545116/0 ediz. 06/2002

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PREXTHERMN
Dear Customer,
Thank you for having chosen the PREXTHERM 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 PREXTHERM 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.
Important warnings
• Thismanualprovidesimportantindicationsonthesafety
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,
accordingtoitscharacteristics,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, animals orthings.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
0085
1QGDX05B
028693 3301698
EN303 - Appr.No.
PIN
Type
N°0000000000
MAX. MIN.
kW
kW
Q (Hi)-INPUT
P -OUTPUT
230 V - ~50 Hz
IPX0D
CE-0085BN0151
PREXTHERM N 107
116 75
107 70
PMS 6 bar - Tmax 100 °C- -H2O 112 I
Electrical power
supply
Max operating pressure
temperature
Manufacturer
Ferroli Spa
Via Ritonda 78A 37047 San Bonifacio (VR) - Italia
PIN
Trade name
Serial number
Max operating
pressure
Heat output
Uselful heat output
Bar code
Water content
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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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
correspondinginstructionmanual. The thermal head betweentheboileroutletand return must not exceed20°C.Thislimitmust be maintained
both during normal operation and in the start-up phase. Higher thermal heads may cause serious problems to the structure of the boiler.
1.4 Shut-down
To shut the boiler down, move the switch 5 (Fig. 1) on the control panel to position “0” and close the fuel on-off valve.
Dangeroffrost:thebestsafeguardinverycoldperiodsistooperatetheboilerandtheutilities,sothattheentiresystemisrunning.Alternatively,
add special antifreeze to the system, in the proportions indicated by the supplier, based on the minimum hypothesised ambient temperature.
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.
THEBOILERMUSTONLYBEINSTALLEDBYQUALIFIED ANDSPECIALISTPERSONNEL,IN COMPLETECOMPLIANCEWITH ALLTHE
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 wall orany other boiler.Leave a freespace of at least100mmon the sidethatthe door
swings towards.
Innormal conditions, theboiler can restdirectly onthe floor, beingalreadyfitted with itsown base made
from metal section bars. Only if the room is very damp should an additional 8 - 10 cm concrete base be
put in.
6
100
mm
550==
Bruciatore
fig. 1
fig. 2
1. OPERATING INSTRUCTIONS
1.1 Control panel
Key
1Ready for electronic control unit
2Thermohydrometer
3Safety thermostat
4Control thermostat, 2 Stages
5Line switch “0 - I - TEST”
6Burner lockout indicator light
Burner

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PREXTHERMN
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. Suitably treated water should be used in the central heating
system, to prevent any possible deposits in the boiler due to hard water, or corrosion due to aggressive water.
Itshouldalsoberememberedthat even minor deposits measuring just a few millimetres thick can cause, due to their low thermalconductivity,
significantoverheating of theplate,with consequent seriousproblems:uniform and localiseddifferential expansion that causesdamage to the
plate and the welding.
2.2 Connecting the burner
Thisappliance is designedfor oil or gasjet burners. Theburner must be chosenaccording to thefield of operation, theoperating pressure and
the size of the combustion chamber. The fuel flow-rate must in any case be set between the max. and min. heat input of the boiler.
Atwo-stageburner should be used, fittedwith anintermediate flangefor fastening theburner supportplate ring3 tothe door4. As regards the
dimensions of the draught tube, the lengths indicated in the table below should be followed, so as to avoid rapid flame reversal with a
consequent increase in the flue gas outlet temperature and a reduction in the efficiency of the boiler.
N.B. -To prevent the door from overheating near the burner support plate, close any cracks between the burner sleeve and the opening in the
door, using an insulating gasket 2. The flexible fuel pipes 8 must be long enough to allow the door to be opened 90°with the burner fitted.
Key
1Flame inspection window
2Insulating Gasket
3Burner support plate
4Front door
6Turbulators é
Model PREXTHERM N 107 180 300
mmA 160
mmB 145 160
145 180 160
2.3 Electrical connections
THEBOILERSHOULDBECONNECTEDTOASINGLE-PHASE,230VOLT-50HZELECTRICALLINE,USINGAPERMANENTCONNECTION,
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 professionally qualified personnel checkthe efficiencyandthe rating of theearth system. The manufacturer
isnot liable forany damage caused bythe appliance notbeing correctly earthed. Inaddition, make surethat 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.

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Mod. 107
R side H 912
L side H 912
Cover L 760
n°1
n°1
n°1
Mod. 180
R side H 912
L side H 912
Cover L 760
n°1
n°1
n°1
Mod. 300
R side H 1012
L side H 1012
Cover L 850
n°1
n°1
n°1
Reversible side h 912
Cover L 760 n°2 n°1
Reversible side H 1012
Cover L 850 n°2 n°1
A
2.4 Flue connections
The boiler should be connected to a suitable flue, manufactured in compliance with the standards in force. The pipe between the 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.
In normal conditions, the stack must operate in depression, overcome the drag, have an air-tight seal and be smooth on the inside, be made
from material resistant to high temperatures and corrosion, and feature inspection openings. The walls should be suitably insulated to prevent
excess cooling of the flue gases
For systems with more than one boiler, each boiler must have a stack that is separate or insulated from the adjacent ones. No other discharge
can be connected to the boiler stack.
2.5 Assembling the casing
The boiler is supplied in 3 separate boxes, containing the Casing, the Control panel and the Boiler body.
Follow the instructions below for the assembly of the casing and the control panel.
D Prepare and fasten the right and left sides, following
the summary table in point “B”.
CFit the “pin holder springs” “1” and the cable glands “2”.
ABoiler body
BSide assembly summary table.

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PREXTHERMN
I
B
A
E Fasten the 2 front “side support brackets” “1”.F Position the sides.
G Fasten the sides at the front “H1” and rear “H2” H Fit the wiring protection box “A” using the screws “B” on
the sides, and position the pre-wired control panel.
IFit the control panel to the sides using the tabs “A”. Place the
reinforcement spring “B” between the head of the screw and the tab. L Fit the cover or covers.
M Insert the “lip seal” on the edge of the smokebox. N Fasten the smokebox by
tightening the corresponding
screws.

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2.6 Adjusting the door
Opening
To fasten the opening side of the door, simply tighten the locknuts 2 and 4 towards nuts 1 and 3.
To reverse the opening side, move locknut 2 to the opposite side at the bottom, and vice-versa for locknut 4.
Seal
Loosen locknuts 2 and 4; tighten nuts 1 and 3 as required; then tighten locknuts 2 and 4.
Positioning
After having fitted the burner, the door may need to be positioned. To do this, loosen the dowel 5 and adjust the nut 6. Ensure that the seal
gasket is compressed against the ledge.
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 performedon firstignition, andafterall maintenance operations thatinvolve thedisconnection oftheappliancefrom 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 burner anchor ring and smokebox are sealed. If flue gas leaks from the door, adjust the corresponding screws so as to further
compress the gasket against the ledge, at the point where the leaks occur.
2Theburnerisworkingcorrectly.Thischeckshouldbeperformedusingtherequiredinstruments,following the 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.

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4. TECHNICAL SPECIFICATIONS
Water
pressure
drop
Model
Prextherm N 107
Prextherm N 180
Prextherm N 300
116
196
326
Max
75
140
210
Min
Heat
output
kW
107
180
300
Max
70
130
196
Min
Heat input
gas+oil
(NHV)
kW
112
156
239
Water
content
dm3
6
6
6
Operating
pressure
bar
1
2
4
∆t 20°C
2,5
4,5
8,0
∆t 10°C
Model
Prextherm N 107
Prextherm N 180
Prextherm N 300
0,38
1,60
2,09
Combustion
chamber
load loss
∆p mbar
310
361
412
Body
weight
kg
Combustion chamber
0,38
1,60
2,09
Volume
m3
806
1146
1306
Lenght
mm
400
400
450
Ø
mm
Dimensions
760
760
850
A
mm
420
420
465
B
mm
482
482
525
C
mm
870
1220
1420
D
mm
873
1223
1423
E
mm
1000
1000
1100
F
mm
80
80
90
G
mm
900
900
1000
H
mm
DN50
DN50
DN65
Ø1
mm
DN50
DN50
DN65
Ø2
mm
180
180
250
Ø3
mm
fig. 3
3.4 Maintenance
To ensure the maximum reliabilityof theheating systemand minimumrunningcosts, theboiler mustbe cleanedregularly,at least oncea year.
These maintenance operations must be performed by qualified and specialist personnel.
In any case, it is good practice to check the condition inside the boiler once a week, by opening the front door, so as to avoid anomalous
operation for extended periods. During this operation, all the turbulators should be removed longitudinally, so as to prevent them from
becoming clogged due to the inevitable deposits of soot.
Cleaning the boiler
1Disconnect the power supply to the boiler
3Open the door by unscrewing the knobs.
4Carefully clean the tube bundle: open the front door of the boiler completely, and remove all the turbulators from the tubes. Thoroughly
clean the tube bundle using the brush. Remove the soot deposits from the rear smokebox, through the door. Brush and scrape the furnace
to remove the deposits of sulphur and other solid substances. Check the nozzles and the position of the burner combustion head, in the
event where carbon deposits are formed (to clean the burner, always refer to the instructions provided by the manufacturer).
5Close the door again, and fasten it using the knob.
Descaling the boiler
Itis extremely important, aboveallin areas wherethe water is veryhard, to periodicallyde-scale,or better still, toinhibitthe formation of lime-
scale deposits in the system. These periodical or continuous operations are indispensable for extending the life of the boiler and preventing
localised overheating of the metal plate, differential expansion or thermal shock. Therefore, after the first operating season at the latest,
thoroughdescalingshouldbeperformed Thisoperationmustbe repeatedattheendof theheatingperiod.Ifcontinuousdescalingispracticed,
itis essential to use a safe and absolutely non-corrosive product. In addition, it is essentialtoperiodicallyremovetheslimethat deposits inside
the boiler, through the special fitting.
For gas burners, decrease the pressure in the combustion chamber by 15%

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Key
32 Pump (not supplied)
49 Safety thermostat
72 Room thermostat (not supplied)
98 Switch
114 Water pressure Switch
159 Test knob
fig. 4
fig. 5
160 Auxiliary contact
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