Ferroli PREXTHERM N 107 User manual

PREXTHERM N
107 - 145 - 180 - 240 - 300
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
HEIZKESSEL AUS GUSSEISEN MIT HOHEM WIRKUNGS-
GRAD FÜR FLÜSSIGE un /o er GASFÖRMIGE BRENN-
STOFFE
INSTALLATIONS-, BEDIENUNGS- UND ARTUNGSAN-
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
AAN IJZINGEN 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. 3545135/0 ediz. 05/2003

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PREXTHERM N
Dear Customer,
Thank you for having chosen the PREXTHERM N, an a vance -concept Ferroli
boiler featuring cutting-e ge technology, high reliability an constructional quality.
Carefully rea this manual an keep it for future reference.
The PREXTHERM N is a high-efficiency heat generator for the pro uction of hot
water for heating purposes, suitable for operation with jet burners on gas or liqui
fuel.
Important warnings
• This manual provi es important in ications on the safety
of operation, installation an maintenance, an is an
integral an essential part of the pro uct. Rea this
manual before installation an operation. It shoul be
carefully kept for future reference.
• This appliance must only be use for the purposes it
has been specifically esigne for. This appliance is
use to heat water to below-boiling temperatures at
atmospheric pressure, an must be connecte to a
heating an /or omestic hot water istribution system,
accor ing to its characteristics, performance an heating
capacity. All other uses are consi ere improper an
thus angerous.
• The appliance may not be opene nor its components
tampere with, except for the parts inclu e in the
maintenance operations. The appliance may not be
mo ifie to alter its performance or use.
• The installation an maintenance operations must be
performe accor ing to the stan ar s in force, the
instructions of the manufacturer an must be carrie
out by professionally qualifie personnel.
• Incorrect installation or poor maintenance may cause
amage to people, animals or things. The manufacturer
eclines all liability for amage eriving from errors in
the installation an operation of the appliance, an in
any case from the failure to observe the instructions
provi e .
• Before performing any cleaning or maintenance
operations, isconnect the appliance from the mains
power supply using the system switch an /or the
correspon ing on-off evices.
• In the event of faults an /or poor operation of the
appliance, it shoul be eactivate . Do not attempt to
repair the appliance. Contact professionally qualifie
personnel only.
• After having remove the packaging, check that the
contents are intact. The parts of the packaging must
not be left within the reach of chil ren, as they are
potential sources of anger.
ENGLISH
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)

PREXTHERM N
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21 4 53
1.2 Ignition
Move the main switch 5 to 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. The thermal head between the boiler outlet and return must not exceed 20 ° C. This limit must 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.
Danger of frost: the best safeguard in very cold periods is to operate the boiler and the utilities, so that the entire system is running. 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 3 and 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 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
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.
In normal conditions, the boiler can rest directly on the floor, being already fitted with its own 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
7
100
mm
550==
Bruciatore
fig. 1
fig. 2
1. OPERATING INSTRUCTIONS
1.1 Control panel Key
1 Ready for electronic control unit
2 Thermohydrometer
3 Safety thermostat
4 Control thermostat, 2 Stages
5 “0 - I - TEST” boiler switch
6 Burner lockout indicator light
7 Burner (not supplied or supplied separately)
Burner

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PREXTHERM 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 5 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.
It should also be remembered that even minor deposits measuring just a few millimetres thick can cause, due to their low thermal conductivity,
significant overheating of the plate, with consequent serious problems: uniform and localised differential expansion that causes damage to the
plate and the welding.
2.2 Connecting the burner (fig. 3)
This appliance is designed for oil or gas jet burners. The burner must be chosen according to the field of operation, the operating 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.
A two-stage burner should be used, fitted with an intermediate flange for fastening the burner support plate ring 3 to the door 4. 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 fuel coupling hoses must be long enough to permit opening the door by 90 ° with the burner fitted.
Key
1 Flame inspection window
2 Insulating Gasket
3 Burner support plate
4 Front door
5 Turbulators é
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 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.
1
3
2
4
5
A
ØB
fig. 3
Model 107 180 300
(minimum) mmA 160
mmB 145
160
145
180
160
145
160
145
240
180
160

PREXTHERM N
5
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Mod. 107
Mod. 145
R si e
L si e
Cover
n° 1
n° 1
n° 1
Mod. 180
Mod. 240
Mod. 300
R si e
L si e
Front cover
n° 1
n° 1
n° 1 Reversible si e
Rear cover
n° 2
n° 1
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.
C Couple and secure the right and left side
panels, following the summary table at
point “B”.
D Fit the “pin holder springs” “1” and the cable glands “2”.
A Boiler body
B Side assembly summary table.
1
2
A

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PREXTHERM N
E Fasten the 2 front “side support brackets” “1” . F Place the sides on the boiler shell.
G Secure the sides at the front and rear. H Fit the wiring protection box “1” using the screws “2” on
the sides, and position the pre-wired control panel.
I Fit the control panel to the sides using the tabs “1”. Place the
reinforcement spring “2” between the head of the screw and the tab.
M Fit the covers following the sequence given in point “B”.
1
1
2
I
1
2
123
L Wiring connections to the boiler:
- have the burner connection cables come out of the
bottom of the right-hand side if you want the door to
open to the right or vice versa the left-hand side.
- connect the specific connector to the pressure switch
1 and the pressure gauge coupling to the sheath 2.
- insert the thermostat and thermometer bulbs fully
inside the sheath 3, fastening them with the clip.

PREXTHERM N
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2.6 Opening and adjusting the door
Opening
The burner door can be opened to the right or to the left by simply loosening the 2 nuts
to the right or left of part 1.
Seal and horizontal adjustment
Screw down the lock nuts 2; screw down the nuts 1 as much as necessary; then lock
the lock nuts 2.
Positioning and vertical adjustment
After fitting the burner, it may be necessary to reposition the door. This is possible by
loosening the grub screw 3 and turning the nut 4. It will be necessary for the entire
sealing bead 5 to be under pressure on the stop.
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:
a the system is filled at the right pressure and any air has been correctly vented;
b there are no water or fuel leaks;
c the electrical power supply is correct;
d all the flues have been installed correctly and not too near to or across any flammable parts;
e there are no flammable substances near the appliance;
f the burner is suitably sized for the output of boiler;
g the water on-off valves are open.
First ignition
After having carried out the preliminary checks, the following ignition operations can be performed:
1 Open the fuel on-off valve.
2 Set the thermostat 4 (Fig. 1) to the desired value.
3 Close 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:
1 The 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.
2 The burner is working correctly. This check should be performed using the required instruments, following the manufacturer’s instructions.
3 The thermostats are working correctly.
4 Water is circulating in the system.
5 The 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.
fig. 4
5
4
3
1
2

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PREXTHERM N
4. TECHNICAL SPECIFICATIONS
ater
pressure drop
Model
Prextherm N 107
Prextherm N 145
Prextherm N 180
Prextherm N 240
Prextherm N 300
116
158
196
251
326
Max
75
102
140
172
210
Min
Heat
output
k
107
145
180
240
300
Max
70
95
130
150
196
Min
Heat input
gas+oil (NHV)
k
112
131
156
272
239
ater
content
dm3
6
6
6
6
6
Operating
pressure
bar
1
1,5
2
3
4
∆t 20°C
2,5
3,5
4,5
6,5
8,0
∆t 10°C
Model
Prextherm N 107
Prextherm N 145
Prextherm N 180
Prextherm N 240
Prextherm N 300
Combustion chamber Dimensions
760
760
760
850
850
A
mm
420
420
420
465
465
B
mm
482
482
482
525
525
C
mm
873
1023
1223
1323
1423
D
mm
860
1010
1210
1310
1410
E
mm
1000
1000
1000
1100
1100
F
mm
80
80
80
90
90
G
mm
900
900
900
1000
1000
H
mm
340
360
400
430
450
Ø6
Boiler outlet
1”
1”
1”
1”
1”
Ø5
Condensate outlet
3/8”
3/8”
3/8”
3/8”
3/8”
Ø4
For safety equipment
1”
1”
1”
1”
1”
180
180
180
250
250
Ø3
mm
Flue
DN50
DN50
DN50
DN65
DN65
Ø2
mm
System return
DN50
DN50
DN50
DN65
DN65
Ø1
mm
System delivery
804
944
1144
1214
1304
Lenght
mm
400
400
400
450
450
Ø
mm
0,10
0,12
0,14
0,19
0,21
Volume
m3
0,38
0,90
1,60
1,85
2,09
Connections
∆p mbar∆p mbar
Boiler weight
with no load
kg
Combustion
chamber
load loss
∆p mbar
Ø4
Ø5
Ø6
fig. 5
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.
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
1 Disconnect the power supply to the boiler
3 Open the door by undoing the 2 nuts (see 2.6).
4 Carefully 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).
5 Close the door again, and fasten it using the knob.
Descaling the boiler
It is extremely important, above all in areas where the water is very hard, to periodically de-scale, or better still, to inhibit the 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,
thorough descaling should be performed This operation must be repeated at the end of the heating period. If continuous descaling is practiced,
it is essential to use a safe and absolutely non-corrosive product. In addition, it is essential to periodically remove the slime that deposits inside
the boiler, through the special fitting.

PREXTHERM N
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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
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
fig. 6
fig. 7
Main wiring diagram
Electrical connection diagram