gn boiler range

GN Boiler range15kW - 650kW floor standing cast iron range of boilers10 year manufacturers guarantee on the cast iron

2

Ferroli boilers are manufactured from high quality cast iron and aredesigned for a reliable long life –with a 10-year manufacturer’sguarantee on the cast iron work.Subject to commissioning by Ferroli,there is also a 2-year manufacturer’sguarantee on parts and labour.

All GN models are suitable fornatural gas, LPG or oil-fired pressurejet burners, with a duel fuel option.

The models in the GN range are:

GN1 23.3 kW to 93 kW

GN2 90 kW to 252 kW

GN4 200 kW to 650 kW

The GN range is a highly efficientboiler with on/off, high/low ormodulating burner operation. Wecan also supply pre-mix burnerswhich are fully modulating, low noxand quiet. The individual sectionshave been developed to achieve thehighest boiler efficiency in order toreduce fuel consumption. The boiler

body is insulated with high densitymineral fibre to minimise heat lossfrom the heat exchanger.

GN1 and GN2 models have adouble-pass heat exchanger, whilstthe GN4 has a triple-pass heatexchanger for maximum heattransfer and ultra-high operatingefficiency.

The GN range is designed for usewith fully pumped indirect systemsoperating at working pressures upto 6bar at 90ºC flow temperature.

The pre-wired control panel ishoused in a stylish casing andincorporates: on/off illuminatedswitches; high/low thermostaticcontrol with limit thermostat(manual re-set); and a temperatureand pressure gauge.

The boilers are designed with frontaccess for ease of maintenance andthe clearance required at the side ofthe boiler is kept to a minimum.

This makes the GN modelsparticularly suitable for modularinstallations.

The Ferroli Enerstep Stage 9 highperformance sequence controller isspecifically designed for use withFerroli boilers in the commercialheating and venting market.

It gives significant efficiencyimprovements that can give majorfuels savings on cast iron boilers.The system comprises: a plug-inmain control unit supported byancillary control elements;temperature sensors to giveweather compensation, optimumstart, night set back and frostprotection; and interface modulesetc that allow almost anyspecification of boiler sequencecontrol mode to be supplied. TheEnerstep Stage 9 will control up to18 boilers with full optimum startfacility which will provide inside andoutside weather compensation.

The Ferroli GN Boiler range

GN Boiler range15kW - 650kW floor standing cast iron range of boilers

Boiler installation requirementsThank you for choosing Ferroli. This manual provides important informationon safety of operation, installation & maintenance, and is an integral andessential part of the product. Please read this manual before installation, itwill be required for future reference.

This data must be diplayed on the appliance

Our preferred position being - right hand side, front, top. If not displayedguarantee will be invalid.

Please note: If you have not received your data plate or you have mislaid itplease contact Ferroli Commercial for a duplicate Immediately.

FERROLI Ferroli Spa Via RitoSab B

EN303 – App NoPIN

TYPE GN4 N 07Serial No000000000

1QGDX8

8 0286393303169

Heat input 217 128

kWHeat outputk

C97,02G07CE0085AS05

3

850

. .

711

80

542

Q

A400

270 B

a1

a2

a3

1

2

3

45

1"

1"

Boiler control panel

Key1. Blank socket2. Thermometer / pressure gauge3. High limit stat manual reset4. Main switch5. Control thermostat

GN1

Boiler Model GN1No sections 02 03 04 05 06 07 08Boiler output (High Fire)kW 23.3 34.9 46.5 58.1 69.8 81.4 93.0Boiler output ( Low Fire) kW 15.0 15.0 32.5 40.5 48.8 57.0 65.0Boiler input (gross) (High Fire) kW 28.6 43.0 57.3 71.6 86.1 100.4 114.7Boiler input (gross) (Low Fire) kW 18.2 18.2 39.3 49.1 59.1 68.8 78.6Boiler input(nett) Gas/ Oil (High Fire) kW 25.8 38.7 51.6 64.5 77.5 90.4 103.3Boiler Input (nett) Gas/ Oil (Low Fire)kW 16.4 16.4 35.4 44.2 53.2 62.0 70.8Water content litres 11 14 17 20 23 26 29Design flow rates @ ∆t 11ºC litres/sec 0.51 0.76 1.01 1.26 1.52 1.76 2.01Waterside pressure drops @ ∆t 11ºC mb 1.0 1.8 4.2 7.2 11.0 15.0 20.0Design flow rates @ ∆t 20ºC litres/s 0.28 0.42 0.55 0.69 0.83 0.97 1.1Waterside pressure drops @ 20ºC∆t mb - - 1.0 1.6 2.3 3.3 4.5Maximum water pressure bar 6 6 6 6 6 6 6Minimum static head m 2.1 2.1 2.1 2.1 2.1 2.1 2.1Minimum flow rate litres/s 0.2 0.3 0.4 0.5 0.6 0.7 0.8Input gas rate (High Fire) m3 2.18 3.26 4.35 5.42 6.52 7.60 8.69Working pressure boiler nat gas mb 20 20 20 20 20 20 20Max gas inlet pressure boiler nat gas mb 25 25 25 25 25 25 25Burner pressure as per burner manufactures dataApprox flue gas volume @ 9% CO2 @ NTP m3/h 56.3 87.25 117.5 136.1 182.7 213.7 248.7Approx flue gas temp nett (primary flue) ºC 220 220 220 220 220 220 220Gas inlet connection as per burner manufacturer dataWater flow/return connections a1 & a2 ins 1 1/2 1 1/2 1 1/2 1 1/2 1 1/2 1 1/2 1 1/2Drain cock a3 ins 3/4

3/43/4

3/43/4

3/43/4

Draught required @ boiler flue outlet mb 0.02 0.02 0.02 0.02 0.02 0.02 0.02pascal 2 2 2 2 2 2 2Flue connection nominal dia mm 130 130 130 180 180 180 180Electrical supply 230 v 50Hz single phase Yes Yes Yes Yes Yes Yes YesCombustion chamber length mm 286 386 486 586 686 786 886Boiler length A mm 300 400 500 600 700 800 900Blast tube diameter B mm 105 105 105 105 125 125 125Flue diameter Q mm 130 130 130 180 180 180 180Pressure drop load loss ∆t p mb 0.2 0.2 0.02 0.2 0.2 0.2 0.2Combustion chamber volume litres 12.09 20.15 28.21 36.27 52.39 60.45 68.51Water load loss ∆t 10ºC 1 1.8 4.2 7.2 11 15 20

∆t 20ºC - - 1 1.6 2.3 3.3 4.5Weight kg 75 100 125 150 175 200 225Water content litres 11 14 17 20 23 26 29Front clearance min mm 750 750 750 750 750 750 750Rear clearance min mm 800 800 800 800 800 800 800Side clearance min mm 50 50 50 50 50 50 50MAXIMUM WATER FLOW TEMPERATURE 90º CMINIMUM RETURN TEMP 45ºC

4

GN2 Q

A

1

2

3

45

a1

a2

1196

600

375

Ba3

867

84

726

A1 Central heating flow DN80 3"A2 Central heating return DN80 3"A3 Boiler drain 3/4"



Boiler Model GN2No sections 05 06 07 08 09 10 11 12 13 14Boiler Output High Fire kW 90 108 126 144 162 180 198 216 234 252Boiler Output ( Low Fire) kW 73 87 101 115 129 143 157 171 185 199Boiler Input (gross) High fire gas + oil kW 98.8 117.4 136.9 156.5 176.0 195.6 215.2 234.7 254.3 273.9Boiler Input (gross) Low fire gas + oil kW 80 95 110 125 140 155 170 185 200 215Water Content litres 49 57 65 73 81 89 97 105 113 121Design flow rate @ ∆t11ºC litres/sec 1.95 2.35 2.74 3.13 3.52 3.91 4.3 4.7 5.01 5.47Waterside Pressure loss @ 11ºC∆t mb 2.8 3.4 4.8 6.5 8.5 11 13 16 19 23Design flow rate @ 20ºC∆t litres /s 1.07 1.29 1.50 1.72 1.93 2.15 2.36 2.58 2.79 3.00Waterside Pressure loss @ 20ºC∆t mb - - 0.5 0.8 1.8 2.2 2.6 3.2 4.0 4.5Maximum water pressure bar 6 6 6 6 6 6 6 6 6 6Minimum Static head m 2.1 2.1 2.1 2.1 2.1 2.1 2.1 2.1 2.1 2.1Minimum flow rate litres/s 0.72 0.86 1.0 1.15 1.29 1.43 1.58 1.72 1.86 2.0Input Gas Rate High Fire m3 13 15 17 20 22 24 27 29 32 33Working pressure boiler Nat gas mb 20 20 20 20 20 20 20 20 20 20Max gas inlet gas pressure mb 25 25 25 25 25 25 25 25Draught required @ boiler flue outlet mb 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02pascal 2 2 2 2 2 2 2 2 2 2Burner pressure as per burner manufacturers dataApprox flue gas volume @ NTP m3 140 159 196 218 247 273 305 326 370 402Approx flue gas temp ºC 220 220 220 220 220 220 220 220 220 220Boiler flue gas resistance mb 0.3 0.31 0.32 0.33 0.34 0.36 0.37 0.38 0.39 0.40Electrical supply 230 v 50Hz Yes Yes Yes Yes Yes Yes yES Yes Yes YesCombustion chamber pressure drop ∆p mb 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4Combustion chamber volume litres 63 77 91 104 118 132 146 160 174 187Boiler length A mm 647 757 867 977 1087 1197 1307 1417 1527 1637Blast tube diameter B mm 130 130 130 154 154 154 154 154 154 154Flue diameter Q mm 180 180 200 200 200 200 200 200 200 200Water flow/return connections a1, a2, ND 80 3 3 3 3 3 3 3 3 3 3Drain cock a3 ins 3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4Gas Inlet connection as per burner manufacturers dataWeight kg 310 361 412 463 514 565 616 670 725 780Front clearance min mm 1000 1000 1000 1000 1000 1000 1000 1000Rear clearance min mm 800 800 800 800 800 800 800 800Side clearance min mm 200 200 200 200 200 200 200 200MAXIMUM WATER FLOW TEMPERATURE 90º CMINIMUM RETURN TEMP 45ºC

5

542

Q

A

1

2

3

45

B1 B2

A1

A2

1193

850

463

B



Boiler Model GN4No sections 07 08 09 10 11 12 13 14Boiler Output High Fire kW 200 250 300 360 420 480 560 650Boiler Output ( Low Fire) kW 120 150 180 215 250 290 330 390Boiler Input (gross) High fire gas + oil kW 217 270 324 388 452 516 600 695Boiler Input (gross) Low fire gas + oil kW 128 160 192 229 266 309 352 416Water Content litres 143 163 183 203 223 243 263 283Design flow rate @ 11ºC∆t litres/sec 4.32 5.39 6.46 7.75 9.08 10.4 12.1 14.1Waterside Pressure loss @ 11ºC∆t mb 66 99 139 178 215 254 292 331Design flow rates @ 20ºC∆t litres/sec 2.58 2.7 3.3 3.87 4.53 5.17 6.03 7.0Waterside Pressure loss @ 20ºC∆t mb 20 30 42 54 65 77 88 100Maximum water pressure bar 6 6 6 6 6 6 6 6Minimum Static head m 2.1 2.1 2.1 2.1 2.1 2.1 2.1 2.1Minimum flow rate litres/s 1.73 2.16 2.6 3.6 3.12 4.16 4.85 5.63Input Gas Rate High Fire m3 20.28 25.23 30.28 36.26 42.24 48.22 56.07 64.95Working pressure boiler Nat gas mb 20 20 20 20 20 20 20 20Max gas inlet gas pressure mb 25 25 25 25 25 25 25 25Burner pressure as per burner manufacturers dataApprox flue gas temperature Net temperature (primary flue)ºC 200 200 200 200 200 200 200 200Approx flue gas volume @ 9% Co2 @ NTP m3/h 318 393 468 558 646 734 848 977Draught required @ boiler flue outlet mb 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02pascal 2 2 2 2 2 2 2 2Water flow/return connections A1,A2,B1,B2. ND 80 weld 3" 3" 3" 3" 3" 3" 3" 3"Gas Inlet connection as per burner manufacturers dataElectrical supply 230 v 50Hz Yes Yes Yes Yes Yes Yes Yes YesCombustion chamber length mm 880 1010 1140 1270 1400 1530 1660 1790

dia 500 500 500 500 500 500 500 500Boiler length A mm 1040 1170 1300 1430 1560 1690 1820 195Flue diameter Q mm 180 180 250 250 250 250 250 250Pressure drop load loss ∆p mb 0.5 0.8 0.7 1.0 1.4 1.7 2.6 3.5Combustion chamber volume litres 161.3 185.1 208.9 232.8 256.6 280.4 304.3 328.1Weight kg 940 1050 1170 1270 1400 1510 1630 1740Water content litres 143 163 183 203 223 243 263 283Front clearance min mm 1000 1000 1000 1000 1000 1000 1000 1000Rear clearance min mm 800 800 800 800 800 800 800 800Side clearance min mm 200 200 200 200 200 200 200 200MAXIMUM WATER FLOW TEMPERATURE 90º CMINIMUM RETURN TEMP 45ºC

Selection of flow and return connectionsFor boiler changeover projects and particularly those oldersystems with high water volumes operating with ∆t up to 30oCthen the options to use flow (B1) and top return (B2) may beconsidered.

For traditional systems operating on a ∆t of 11oC then top flow(A1) and bottom return (A2) may be used although it is amandatory requirement that a shunt pump is fitted and it isrecommended that for circulation purposes a flow equivalentto ∆t 25oC is applied. Any shunt pump must be provedrunning before the boiler fires.

Minimum flow rate @ ∆t 25oCBoiler model 07 08 09 10 11 12 13 14

Duty l/s 1.9 2.37 2.84 3.41 3.99 4.55 5.3 6.2

GN4

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British StandardsBS 3456, Part 201: Electrical standards.BS EN 60335, Part 1: Safety ofhousehold & similar electricalappliances.BS 5925: Ventilation principles anddesign for natural ventilation.BS 5440; Part 1, Part 2 Installation &maintenance of flues.BS 6644: Installation of gas fired hotwater boilers – 60kW to 2mW.BS 6700: Design, installation, testingand maintenance of services supplyingwater for domestic use.BS6891: Installation of low-pressuregas pipe-work of up to 28 mm indomestic premises.BS 7074: Application selection andinstallation of expansion vessels andancillary equipment for sealed hotwater systems Part 2: Code of practicefor medium temperature hot watersystems. BS 7593: Flushing of systems. CP 342: Centralised hot water supply.Part 2: Buildings other than dwellings.

Institute of GasEngineers & ManagersPublicationsIGE/UP/1/Edition 2. Tightness testingand purging of industrial and

commercial gas Installations.

IGE/UP/1A/ Edition 2. Tightnesstesting and purging of small industrialand commercial gas Installations.

IGE/UP/2 Edition 2. Gas installationpipework, boosters and compressorsin industrial and commercial premises.

IGE/UP/4. Commissioning of gas firedplant industrial and commercialpremises.

IGE/UP/10/ Edition 2. Installation ofgas appliances in industrial andcommercial premises. Part 1: fluedappliances.

Other publicationsGas Safety Regulations 1998.Building Regulations Parts F and J.

Boiler sitingThe boiler should be positioned on alevel, non-combustible surface thatcan adequately support its weightwhen full of water and connected toancillary equipment. Suitableclearances are required for access,servicing and maintenance – seedimensions and layout.

Water systems –modular installationsFlow and return headers should beconnected in a "reverse return"arrangement, (water flow in eachheader flows the same direction)providing equal flow through eachboiler. This ensures the pressure lossacross any number of boilers willnever be greater than the header lossacross one boiler plus the associatedpipework of the header (See SystemLayout Page).

Care should be taken during the initialstages of design and layout to takeinto consideration adequate waterflow through the boiler, and theinfluence of system controls. Controlvalves and system controls, whenfitted, should be regulated to avoidlower flows occurring. The minimumrecommended flow at any timecorresponds to a 22ºC temperaturerise across the boiler. A minimumreturn temperature of 45ºC should bemaintained.

Appliance &installation design

All boilers must be installed by a competent person and in accordancewith relevant requirements of Gas Safety Regulations, I.E.E. Regulationsand by-laws of the local water authority. The following relevant BritishStandards and Institute of Gas Engineers Publications should be used inrelation to the installation of this boiler range and associated pipework.

Boiler Open Vent Size Cold Vent Size

≤ 60kW 25mm (1") 19mm (3/4")

60 kW – 150kW 32mm (11/4") 25mm (1")

150 kW – 300kW 38mm ( 11/2") 32mm (11/4")

300 kW – 600kW 50mm (2") 38mm (11/2")

EVOPLATE

Reduced hot water storage up to 75%

less then a traditional storage calorifier.

Lightweight with minimum footprint.

Achieve the maximum possible

performance from condensing boiler

installations.

Reduced downtime and maintenance.

Integral dual action domestic water

pump ensuring constant flow through

the exchanger and reducing the risk

from legionnaire’s disease.

7

Sealed systems,pressure relief valvesEach boiler, or in a modular installationeach bank of boilers, must be fittedwith a pressure relief valve to BS 759or BS 6759 Part 1 and sized as shownin BS 6644.

BS 6644 provides the necessaryinformation for the selection andlocation of safety valves and attentionis drawn to the higher capacityrequirements of safety valves forpressurised hot water systems.

System head openvented systemsThe minimum system static head is tobe no less than 2.1m. An independentcold feed and expansion pipes are tobe installed in accordance with BS6644: Section 2 Item 10. For single andmultiple boiler installations, they willnot be smaller than shown in the tableabove. The minimum head must beincreased if necessary to comply withminimum head specified by the pumpmanufacturers in order to avoidcavitation.

CommissioningFerroli recommends that all boilers arecommissioned by its own engineers.On completion, a commission andemission form and Ferroli benchmarkbook will be issued to record anymaintenance and service work. There isa two-year parts and labour warrantyon the boiler/burner when the boiler iscommissioned by Ferroli.

Water treatment forhot water boilers.Irrrespective of the watercharacteristics, unless the initial fillwater from the mains is treated therewill always be corrosion within aheating or hot water system. Water in aclosed system will also promotecorrosion unless treated. Ferrolistrongly recommends that, wherenecessary, the system should beflushed hot and cold with proprietarycleaner before the use of a stableinhibitor that will not require toppingup to combat the effects of hardnesssalts and corrosion on the heatexchanger of the boiler and associatedsystem. Specialist water treatmentsuppliers, such as Sentinel or Fernox,will advise on all treatment issues anddosage requirements. Flushing shouldbe in accordance with therequirements of BS: 7593.

Example 2Combined heating & domestic hot water with diverter valve on DHW and Mixing vavle on heating.

Example 3Heating only, with separate temperature conpensation on each zone.

Example 1Reverse return header arrangement.

Boiler 1 Boiler 2 Boiler 3 Boiler 4

Boilerprimarypump Heating

pump

ReturnCommonheader

Heatingload

Boiler 1 Boiler 2 Boiler 3

Boilerprimarypump

Heatingpump Heating

load

Commonheader

Bypass

Mixingvalve

Divertervalve

Flow

Return

Watersensor

Sequencecontroller

1 2 3

Sequencecontroller

1 2 3

Boiler 1 Boiler 2 Boiler 3

Boilerprimarypump

Watersensor

Commonheader

Flow

Return

Mixingvalve

Mixingvalve

Zonepump

Zonepump

Heatingzone 1

Heatingzone 2

Compensator

Compensator

Typical Low Loss Header

Boiler FlowConnection

Min distance between flow andreturn connection600mm

Min lengthof header1000mm

Boiler ReturnConnection

FlowConnection

ReturnConnection

2” balancedheader

8

Ventilation requirements of hot water boilers (BS 6644)Boiler input gas rate Position of air vent Where to Air vent free area requirement

60 kW – 2 MW High Level Outside Air Total Input kW – 60kW x 2.25cm = ? + 270cm = High level ventilation requirement

60kW – 2 MW Low Level Outside Air Total Input kW – 60kW x 4.5cm = ? + 540cm= Low level ventilation requirement

Ferroli easy guide to ventilation calculationsFor example: 3 boilers in plant room of 217 kw input gas rate each = 651 kW total Free Ventilation

Requirement

High level 651 – 60 = 591 x 2.25 =1329.75 +270 =1599.75cm2 1599.75cm2

Low level 651 – 60 = 591 x 4.5 = 2659.50 +540 0 =3199.50cm2 3199.50cm2

Air supply andventilation An adequate supply of fresh air andventilation for combustion and coolingmust be provided in accordance with BS6644. The air supply must be free fromcontamination to avoid unnecessarycleaning and servicing of the boilers.

� All ventilation provision should be athigh & low level, direct to outside air,and where possible on the sameelevation.

� Where air is supplied by mechanicalmeans into a boiler/plant room, air inshould be by mechanical inlet and airoutlet by natural ventilation(boiler/plant room under positivepressure) and interlocked.

� Where mechanical inlet and outletsystems are applied, the designventilation flow rates should be as perTable 4 of BS. 6644. IGE/UP/10 Part 1Edition 2 section 7.2

� Where a boiler/plant room is belowground level, low-level ventilationshould be ducted to loe level,terminating 300mm above floor levelof the burner level.

� Safety shut down for mechanicalventilation systems should be providedto cause safety shutdown or lockout ofthe boiler(s) in the event of air flowfailure in either inlet or outletventilation ducts.

� These openings must be fitted withgrills that cannot be blocked or flooded.

Fans should be selected to always createa positive pressure in the boiler houserelative to outside air pressure.

Air supplied for boiler house ventilationshould be such that the maximumtemperatures within the boiler houseare:

At floor level (100mm above floor level) 25ºC

At mid level (or 1.5m above floor level) 32ºC

At ceiling level (or 100mm below ceiling level) 40ºC

Air supply and ventilation

9

Gas supply

Type of fitting Per elbow Per tee Per 90º bend20mm 0.5 0.5 0.325mm 0.5 0.5 0.340mm 1.0 1.0 0.350mm 1.5 1.5 0.565mm 2.0 2.0 0.580mm 2.5 2.5 1.0100mm 3.5 3.5 1.5

The gas supply must be installed by a competent person,and in accordance with BS 6891, IGE/UP/2 edition 2, testedto IGE/UP/1 and IGE/UP/1A edition 2. All pipework must beof adequate size and the pressure loss from the meter topoint of use should not exceed 1mb. The following tablegives pipe lengths from a gas meter to point of use with1mb pressure loss for natural gas end to end. The tablemust be used in conjunction with losses of various fittingsshown in the table above.

M3/hr Input Maximum length of gas pipe (from Meter)gas rate 20mm 25mm 32mm 40mm 50mm 80mm 100mm

2.67 28.6 10.5 394.1 43 5 20 575.4 57.3 12 32 81 3066.7 71.6 8 74 56 2118.1 86.1 17 40 155 10409.3 100.4 31 119 80010.7 114.7 28 109 73411.7 125 20 81 55214 150 59 405 156716.35 175 51 345 134018.7 200 36 246 95923.4 250 27 187 73028.1 300 17 122 47832.7 350 13 94 36637.4 400 10 74 29142 450 8 60 23746.7 500 7 50 19751.4 550 6 42 16756.07 600 36 14365.42 700 27 110

For example:

Boilers with a total input of 100kWwith 8 elbows can have amaximum length of 19m of 50mm pipe. Less (8x1.5m) = 107mof pipe run with 1mb pressure loss.

The tables are based on IGE/UP/2Edition 2, the information isprovided for guidance only. All flowrates are in straight horizontal pipeswith 1mb differential betweenends. We have assumed a meteredsupply at 21mb and a maximum of1mb pressure loss for natural gasto point of use.

10

ServicingFerroli will not accept any liabilityresulting from the use of unauthorisedparts or the repair and servicing ofappliances not carried out inaccordance with the company’srecommendations and specifications.

A comprehensive service of theappliance should be carried out atleast once a year by a CORGIregistered installer, and in accordancewith current Gas Safety Regulations.

Warning: Always switch off the gassupply at the nearest isolation valveand switch of and isolate/disconnectthe electrical supply to the appliance,before commencing any work on theappliance.

Initial Lighting1. Check the electrical supply is turned off.

2. Check that all drain cocks are closed,that any stop valves fitted to the flow andreturn pipes are open and that the systemhas been filled and vented correctly.Ensure there are no visible signs ofleakage.

3. Check the gas supply has been testedand purged in accordance with relevantgas safety regulations.

4. Turn off the boiler thermostat.

5. Turn on the gas inlet valve.

6. Press in the overheat reset button.

7. Switch on the electrical supply to the boiler.

8. Ensure ancillary controls are calling for heat.

9. Turn on the boiler thermostat to50% of its scale.

The burner should light at the end ofits ignition period, if not the lockoutwill be illuminated. Press in andrelease the lockout button on thecontrol box. The controls will be resetand return to ignition sequence.

Once the burner has come to full firethe ‘burner on’ light will appear. Whenthe burner has lit check connectionswith LDF. Set boiler thermostat torequired setting.

Once the burner is in operation youshould refer to the burnermanufacturer’s set instructions for thecorrect commissioning of the burnerto the Ferroli boiler. In all cases weadvise individual manufacturers tocommission and setup burners toindividual requirements..

Servicing andMaintenance

11

Spillage checksSpillage and flue flow tests must becarried out to ensure there is no spillageof combustion products from the boilerin accordance with BS 5440:1.

TestingCheck that the burner responds correctlyto manual on/off operation of anycontrols fitted in the gas control circuit.

Check the operation of the flame failuresafety device.

1. Extinguish the main burner/pilot byturning off the main gas inlet valve.

2. The controls will go to lockoutimmediately and the lockout light willilluminate.

3. Turn gas valve on, and press the resetbutton in and release the lockout button.After a period of time the controls resetand the burner will re-light.

4. Complete the commissioning sectionof the boiler logbook.

Water flow ratesthrough boilerWhen commissioning the heating anddomestic hot water system, the shuntpump or primary boiler pump should beadjusted to give the minimum flow rateas per the table when only part of thesystem is in operation for the dissipationof residual heat.

Hand overFull instructions covering routine lightingand operation of the boiler and burner aregiven in the lighting and operationinstructions. These should be locatedadjacent to the boiler.

A practical demonstration of lighting andshutdown of the boiler/burner should begiven to to the owner or responsibleperson. You should give a full description ofthe function of boiler/burner and systemcontrols, and how they are adjusted andoperated.

Explain why the correct ventilation isrequired, and the safe operation of the flue.

Hand the installation and servicinginstructions, user’s instructions and logbook to the customer/responsible personand request they are kept in a safe placeand readily available whenremedial/maintenance work is carried out.

IMPORTANT INFORMATION

Regular maintenance and servicing mustbe carried out at a maximum of 1 yearintervals in order to ensure reliable andefficient operation. Regular maintenancewill prolong the life of the boiler/burner.After completion of service andmaintenance work the logbook shouldbe brought up to date and retained forfurther reference.

All work should be carried out by aCORGI registered engineer in accordancewith current gas safety regulations.

Servicing andMaintenance

12

GN boilers are designed for use withnatural draught flues. Flue systemsshould be designed in accordancewith current regulations.

The boiler is designed for connectionto a single flue system with one boiler,or a common flue header in the caseof a multi boiler installation.

The flue system should be designed tomaintain atmospheric pressure withslight suction at the boiler flueconnection at all times.

If the suction is to exceed 0.0 mb wewould recommend the fitting of adraught stabiliser to the flue system.

The flue system must be self-supporting; access for cleaning isrequired along with maintenancejoints or similar close to the boilerconnection to allow removal of fluebox during servicing.

The design of the flue system mustensure that any condensate whichmay be formed within the system canbe safely drained to a suitable disposalpoint and the flue material used isresistant to the corrosive effects of thecondensate.

GN boilers are suited to installation inbalanced compartments inaccordance with the requirements ofBS 6644.

Ferroli is aware that flue packagesystems are available from variousmanufacturers who offercomprehensive range of flue andchimney equipment for naturaldraught, fan-assisted and fan dilutionapplications. They will provide youwith a full design and installationservice, to incorporate sizing, sitesurvey and approved drawings prior toinstallation.

Flue systems

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Ferroli Pump Selection ChartBoiler Boiler Flow rate Resistance Min Pump Duty Pump Pipe Model Output kW delta t 11oC 20 deg. C 40% of flow Model SizeGN1N 02 23.3 kW 0.5 l/s 0.5 mbar 0.2 l/s UPS 15-60 1"GN1N 03 34.9 kW 0.76 l/s 0.5 mbar 0.3 l/s UPS 15-60 1"GN1N 04 46.5 kW 1.0 l/s 1 mbar 0.4 l/s UPS 15-60 1"GN1N 05 58.1 kW 1.26 l/s 1.6 mbar 0.5 l/s UPS 15-60 1"GN1N 06 69.8 kW 1.52 l/s 2.3 mbar 0.6 l/s UPS 15-60 1"GN1N 07 81.4 kW 1.76 l/s 3.3 mbar 0.7 l/s UPS 15-60 1"GN1N 08 93 kW 2.01 l/s 4.5 mbar 0.8 l/s UPS 15-60 1"

Boiler Boiler Flow rate Resistance Min Pump Duty Pump Pipe Model Output kW delta t 11oC 20 deg. C 40% of flow Model SizeGN2N 05 90 kW 1.95 l/s 0.5 mbar 0.78 l/s UPS 15-60 1"GN2N 06 108 kW 2.4 l/s 0.5 mbar 0.96 l/s UPS25-55 11/4"GN2N 07 126 kW 2.73 l/s 0.5 mbar 1.09 l/s UPS25-55 11/4"GN2N 08 144 kW 3.12 l/s 0.8 mbar 1.25 l/s UPS 25-55 11/4"GN2N 09 162 kW 3.51 l/s 1.8 mbar 1.41 l/s UPS 25-55 11/4"GN2N 10 180 kW 3.9 l/s 2.2 mbar 1.56 l/s UPS 25-55 11/4"GN2N 11 198 kW 4.29 l/s 2.6 mbar 1.72 l/s UPS32-55 11/2"GN2N 12 216 kW 4.68 l/s 3.2 mbar 1.87 l/s UPS32-55 11/2"GN2N 13 234 kW 5.06 l/s 4 mbar 2.03 l/s UPS32-55 11/2"GN2N 14 252 kW 5.45 l/s 4.5 mbar 2.18 l/s UPS32-55 11/2"

Boiler Boiler Flow rate Resistance Min Pump Duty Pump Pipe Model Output kW delta t 11oC 20 deg. C 40% of flow Model SizeGN4N 07 200 kW 4.33 l/s 20 mbar 1.73 l/s UPS32-55 11/2"GN4N 08 250 kW 5.41 l/s 30 mbar 2.16 l/s UPS32-55 11/2"GN4N 09* 300 kW 6.49 l/s 42 mbar 2.6 l/s UPS40-30F 2" GN4N 10* 360 kW 7.79 l/s 54 mbar 3.12 l/s UPS40-60/2 2" GN4N 11* 420 kW 9.09 l/s 65 mbar 3.6 l/s UPS 40-30GN4N 12* 480 kW 10.39 l/s 77 mbar 4.16 l/s UPS 50-30GN4N 13* 560 kW 12.12 l/s 88 mbar 4.85 l/s UPS 50-30GN4N 14* 650 kW 14.07 l/s 100 mbar 5.63 l/s UPS 65-30

*Denotes flanged pump

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Wiring external to the boiler must beinstalled in accordance with theI.E.E. regulations and any localregulations that apply. Wiring mustbe completed in heat resistantcable. For wiring size refer to thetechnical instructions supplied bythe burner manufacturer. The boilercontrol panel requires a 230V, singlephase 50Hz supply.

Fuse ratings for individual boilers aremarked on the appliance date plate.The control panel is supplied withflying lead and plugs for directconnection to a correspondingsocket supplied on the burner.Should a non-standard burner befitted to the boiler the manufacturermust provide Ferroli with asatisfactory wiring diagram to suit itsboiler wiring diagram. Responsibilityfor suitable connections is at the riskof the third party.

The method of connection to themains electrical supply must

facilitate complete isolation of thesingle boiler or bank of boilers witha contact separation of at least 3mmin all poles.

The appliance must be isolated fromthe mains electrical supply in theevent of electric arc welding beingcarried out on any connectingpipework.

The mains isolator must be locatedadjacent to the boiler in a readily-accessible position. The supplyshould only serve one boiler.

Note: Volt-free contact electricalsupplies must also be isolatedwhere fitted. Further detailsregarding connection to electricitysupply are given in BS EN 60335Pt.1 or BS 3456 Pt. 201. Volt-freecontacts are normally to the burner.You are requested to check withburner manufacturers for suitabilityof connection to your controlsystem.

Electricals

Ferroli began producing heating appliances and equipment in Italy during the 1950s. Today the company is still family-owned but now operates ten ultra-modern factories in Europeand is developing new production sites and offices in China,Russia and the Ukraine. The Group employs over 2,200people and produces more than 500,000 boilers per year.

Ferroli LtdLichfield Road Branston Industrial EstateBurton-Upon-Trent Staffordshire DE14 3HDtel 08707 282 882 fax 08707 282 883e-mail: [email protected]

All the information in this guide was correct at the time of printing. Specifications and designsmay be changed due to Ferroli’s policy of continuous product research and development.The statutory right of the consumer are not affected. August 2006.

Ferroli LimitedFerroli began producing heating appliances and equipment in Italy during the 1950s. Today, thecompany is still family-owned but now operates ten ultra-modern factories in Europe, employing over 2,500 people and producing a wide range of wall hung, cast iron and welded steel boilers, makingFerroli one of the largest and most successful heating appliance manufacturers in the world.

Ferroli Domestic HeatingOffering gas wall mounted units with outputs from 5kW to 50kW, Ferroli’s stylish, compact domesticboilers provide maximum comfort with minimal fuel usage. With a choice of conventional, condensingand combi technologies, there’s a boiler to match the heating and hot water requirements of everyhome. In recent years Ferroli has also become a Northern European leader in solar heating, and hasdeveloped underfloor heating systems for the UK market.

Ferroli Commercial and Industrial Heating, Tel: 08707 282 755Ferroli commercial boilers for pressure jet oil, forced air gas or dual-fuel are factory matched with highefficiency burners to provide outputs up to 14,000kW, while meeting the strictest emissions demands.Our range includes high efficiency aluminium, cast iron, steel and stainless steel boilers as well asstainless steel unvented hot water cylinders, pressurisation units and plate heat exchangers. We are alsotaking a lead in developing underfloor and solar heating solutions.

Ferroli Service, Tel: 08707 282 755Once the normal guarantee period on our boilers has expired, coverage can be extended cost-effectivelywith a choice of Ferroli service contracts to suit your budget. All Ferroli service engineers work toBenchmark standards and the Benchmark Code of Practice for the installation, commissioning andservicing of central heating systems, designed to improve the quality of work undertaken by plumbersand heating installers.

Ferroli Spares, Tel: 08707 282 885The rapidly growing popularity of Ferroli as first choice for both domestic and commercial installationsmeans that heating parts stockists offer readily available spares for Ferroli boilers. For less frequentlyneeded items, we maintain a fully-stocked warehouse located centrally in the UK, enabling same-daydespatch of just about any part needed to keep your Ferroli boiler running at optimum efficiency.

Ferroli Training, Tel: 08707 282 891Ferroli understands that well-trained installers are the key to a safe and efficient heating system. That’s why we run comprehensive training courses in our purpose-built facilities for everyone concernedin the installation and servicing of Ferroli’s range of boilers. These courses improve installers’ knowledgeand skills by providing both the theory and the hands-on practical experience essential to maintainingheating system performance and safety.

gn boiler range

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