Ferroli PREXTHERM User manual

06/97
WELDED STEEL BOILER
from 86.000 to 860.000 kcal/H - from 100 to 1000 kW
from 341.000 to 3.410.000 BTU/HR
PREXTHERM
INSTALLATIONS
AND OPERATING INSTRUCTIONS

PREXTHERM
3
Contents
1. Dimensions and technical data
2. Installation
3. Operation
4. Maintenance

PREXTHERM
4
1. DIMENSIONS AND TECHNICAL DATA
A B C D E F G H L M a1 - a2 a3 a4 a5
100 970 760 1110 235 215 145 540 470 660 400 DN 50 1" 1/4 200 160
125 970 760 1260 235 365 145 540 470 810 400 DN 50 1" 1/4 200 160
150 970 760 1410 235 465 195 540 470 960 400 DN 50 1" 1/4 200 160
200 1060 850 1452 306 415 205 585 515 930 480 DN 65 1" 1/4 250 160
250 1060 850 1652 306 515 305 585 515 1130 480 DN 65 1" 1/4 250 160
300 1060 850 1852 306 615 405 585 515 1330 480 DN 65 1" 1/4 250 160
350 1230 1040 1832 484 405 395 670 600 1250 540 DN 80 1" 1/2 300 210
400 1230 1040 2032 484 605 395 670 600 1450 540 DN 80 1" 1/2 300 210
470 1230 1040 2232 484 805 395 670 600 1650 540 DN 80 1" 1/2 300 210
Output kW Input kW Water capac. Pressure drop Working press. Weight
Min. Max. Min. Max. m3dm3*Flue gas mbar **Water mbar bar kg
100 60 100 65 109 0,083 120 0,6 4 5 270
125 75 125 82 136 0,102 142 0,9 7 5 290
150 90 150 98 163 0,124 162 1,1 10 5 320
200 120 200 131 218 0,174 214 0,8 7 5 430
250 150 250 163 272 0,204 247 1,1 10 5 490
300 180 300 196 327 0,241 283 1,4 16 5 560
350 210 350 229 381 0,286 528 1,8 11 5 830
400 240 400 262 436 0,332 598 2,7 15 5 910
470 282 470 307 512 0,378 667 3,6 19 5 980
comb. chamber
volume
Legend
1Boiler shell
2Door
3Burner mounting plate
4Casing
5Door insulation
6Control panel
a1 Flow connection
a2 Return connection
a3 Safety valve tapping
a4 Flue outlet
a5 Burner flange
PREXTHERM 100-470
PREXTHERM
PREXTHERM
FERROLI F
a4
a2
100
B
A
100
40
G
D E F
a1 a3
H
a5
C
FLUE CONDENSE
Ø 3/8
DRAIN OFF Ø 1
50
1
4
23
56
L 240
M
Fig. 1
*technical dates for oil-fired heating; for gas heating you must decrease of 15%
** ∆ t considered: 15 ° C

PREXTHERM
5
Fig. 1b
min 250
a5
DEF 55
C
a3 a1a2
a4
H
H
DRAIN OFF Ø 1"
FLUE CONDENSE
Ø 3/8"
B
A110
12 3
45
6
max G
0 000
L
Ø M
PREXTHERM 550-1000
Output kW Input kW Water capac. Pressure drop Working press. Weight
Min. Max. Min. Max. m3dm3*Flue gas mbar **Water mbar bar kg
550 330 550 359 598 0,574 852 2,2 14 5 1150
620 372 620 404 674 0,647 936 2,8 19 5 1240
800 480 800 522 870 0,867 1060 2,8 18 5 1580
1000 600 1000 652 1087 1,083 1290 4,2 30 5 1830
PREXTHERM
comb. chamber
volume
Legend
1Boiler shell
2Door
3Burner mounting plate
4Casing
5Door insulation
6Control panel
a1 Flow connection
a2 Return connection
a3 Safety valve tapping
a4 Flue outlet
a5 Burner flange
PREXTHERM A B C D E F G H L M a1 - a2 a3 a4 a5
550 1400 1230 2363 746 500 500 340 720 1600 700 DN 100 DN 40 350 240
620 1400 1230 2563 746 700 500 340 720 1800 700 DN 100 DN 40 350 240
800 1540 1365 2570 782 525 620 360 790 1850 800 DN 125 DN 65 400 270
1000 1540 1365 3020 782 975 620 360 790 2300 800 DN 125 DN 65 400 270
*technical dates for oil-fired heating; for gas heating you must decrease of 15%
** ∆ t considered: 15 ° C

PREXTHERM
6
1
2
3
45
6
Key
1Boiler shell
2Door with burner mounting plate
3Flue hood
4Control panel
5Casing
6Insulation
PREXTHERM 100-470
Fig. 2a
Fig. 2b
3
2
451
PREXTHERM 550 -1000
Key
1Boiler shell
2Door with burner mounting plate
3Flue hood
4Casing
5Insulation

PREXTHERM
7
1.01 PACKING AND SHIPMENT
PREXTHERM 100 - 470
The boilers are supply in N°3 pieces:
1 - Boiler shell with door and flue hood
2 - Casing
3 - Control panel
PREXTHERM 550 - 1000
The boilers are supply in N°2 pieces:
1 - Boiler shell with door and flue hood
2 - Casing and control panel
Fig. 3

PREXTHERM
8
Legend
1Boiler shell
2Door
3Flue outlet cover plate
4Control panel fitted with:
4.1 Control thermostat
4.2 High low thermostat
4.3 Limit thermostat
4.4 Thermometer
4.5 Hours run indicator low fire
4.6 Run indicator high fire
4.7 Burner run light
4.8 On/off switch
4.9 Burner connections (electrical)
5Casing (for assembly, see next page)
6Burner door plate
7Combustion chamber sight glass
8Combustion chamber pressure test point
9Pressure gauge and thermostat pocket
10 Thermal insulation
Fig. 4a
PREXTHERM 100-470

PREXTHERM
9
Casing assembly instructions
- Attach the cover supports 21 in their right positions
- Place the coupling clips pos. 23-23.1-23.2 and pins/washers/nuts pos. 22-22.1-22.2 as indicated
- Attach plate 1 with two bolts and nuts M5X16 pos. 20
- Insert the cable collars 2 in the slit in plate 1 resting the panel 4 on the boiler
- Mount the sidings 3 so that they fit over the seat in plate 1
- Open the panel 4, take out the screws 5 and attach the sidings 3 with 6 self-threading screws pos. 6
- Insert the bulbs 9 into sleeves 8, tighten the end of the thermohydrometer 7 into the gauge tap 10
- Attach the back cover 11 togheter with the two cable collars 12 using 8 self-threading screws pos. 6.1
- Mount left cover 13 and right cover 14
- Mount right padded door 16 using 2 self-threading screws pos. 6.2, mount left padded door 15
- Take out of the document envelope the technical specifications label 18 and attach it on siding 2
- REMEMBER to take the cleaning accessories 19 out of the combustion chamber
Fig. 4b
PREXTHERM 100-470
SLIT
SIDING SEAT
23
22

PREXTHERM
10
8
6
78
21
10
9
4
5
3
4.9 4.4 4.6 4.5
4.7
4.8
4.1
4.2
4.3
PREXTHERM 550-1000
Fig. 5a
5Casing (for assembly, see next page)
6Burner door plate
7Combustion chamber sight glass
8Combustion chamber pressure test point
9Pressure gauge and thermostat pocket
10 Thermal insulation
Legend
1Boiler shell
2Door
3Flue outlet
4Control panel fitted with:
4.1 Control thermostat
4.2 High low thermostat
4.3 Limit thermostat
4.4 Thermometer
4.5 Hours run indicator low fire
4.6 Run indicator high fire
4.7 Burner run light
4.8 On/off switch
4.9 Manometer

PREXTHERM
11
8
16 10
13
12
3
3.1
18
20
5
7
8
9115
14
5
21
19
6.1
17 11
6
2
5
4.1
7
4
1
55
7
7
77
5
1
5
5
18
1
1
555
1
- Install the clips 1on side panels 2 and 11, on the front panel 3, on the left back panel 4, and on the jacket support 9.
- Installtheclips5 onthe frontpanels 3and 3.1,on therear panel4.1, onthe sidepanels atthe rearside 6,on theside panelson thefront 6.1(with protection).
- Install springs 7 on the top panels 8, on the front panel 7.1 and on rear panel 4.1.
- Install the control panel 7.1 10 and the cable support 2.1 on the front side panel 11 with 8 self taping screws 12. The control panel is fixed with 2 self tapping
screws 13.
- Install the temperature sensing bulbs 14 in socket 15 and connect the pressure gauge 16 connection to the apposit sensing point.
- Install the cable clamps 17 and wire the electrical connections to the control panel.
- Sequence installing jacket: - side panels 11.2 - top panels 8 - front panel 3 and 3.1 - side panels 6 and 6.1 - top and bottom covers 18 - rear panel 4 and 4.1
- ake out the data badge from the documents envelope 19 and place it on side panel 11
- DON'T FORGET to remove the cleaning tools 20 from the combustion chamer
- NE PAS OUBLIER d'enlever du foyer les accessoires pour le nettoyage 20.
Fig. 5b
PREXTHERM 550-1000
57
1