Ferroli GN2 N Manuel utilisateur

INSTALLATION AND OPERATING

INSTRUCTIONS

GN2

HIGH EFFICIENCY

CAST IRON BOILER

FOR LIQUID and/or

GAS FUELS

2GN2

INDEX

1. Technical information .............................................................................................................................. page 3

2. Dimensional and technical characteristics .............................................................................................. page 3

3. Packing and dispatch ........................... .................................................................................................. page 5

4. Boiler assembly....................................................................................................................................... page 6

5. Shell assembly ....................................................................................................................................... page 11

6. Installation ............................................................................................................................................... page 19

7. Inspections and adjustments................................................................................................................... page 20

8. Maintenance............................................................................................................................................ page 21

9. Boiler parts .............................................................................................................................................. page 22

GN2

Q (m3/h)

Fig. 2

Technical information

1.01 Introduction

GN2 is a new high efficiency heat generatorproducing hot water for heating purposes. It can operate with either

a liquid and/or gas fuel fired burner 1°or 2°stage.

The boiler unit consists of cast iron parts assembled by steel rods and links, the shape of which has been particularly

designed to achieve optimum fin distribution. This ensures high thermal efficiency and consequently high energy

savings. The boiler is insulated by a thick layer of glass wool to reduce heat loss to the minimum.

Fig. 1

2. Dimensional and technical

characteristics

2.01 Load loss characteristics (fig. 2)

Theloadlossesofthehydrauliccircuitpertainingtoeach

boiler model, are specified in the following diagram

which refers to the water flow rates corresponding to

temperatures between 10 and 20°C.

1.02 Function of the adjusting and safety devices

Manually reset safety thermostat 3 (fig. 1)

Thisisactivatedwhenthetemperatureintheboilerduringtheheatingphasereachesavaluebeyondwhichadangerous

condition could be created.

Boiler regulating thermostat 5 (fig. 1)

Used to adjust the temperature in the boiler by means of its adjuster knob. This thermostat controls the 1°or

2°stage burner. In the case of use of 1°stage burner, you must not connect the B2 block (2°stage burner).

Ambient thermostat

This is not standard supply, but can be mounted at the Installer’s charge.

It is connected in series with the regulating thermostat and contemporaneously controls both the burner and the plant

circulator during the heating phase. It is advisable to install this thermostat for greater comfort and energy savings.

Key

1Thermometer

2Arrangement for automatic control

3Mains switch

4Overheat cut-off thermostat

5C.H. boiler thermostat

∆p (mbar)

4GN2

2.02 Dimensional and technical brief (fig. 3 - table 1)

NOTE: - The maximum operational temperature of the plant heating water is 90°C.

Table 1

Fig. 3

Key

a1 - PLANT DELIVERY ND 80 - 3"

a2 - PLANT RETURN ND 80 - 3"

a3 - 3/4" BOILER DRAIN

A600

1086

867

726

375

a2 a3

090

120

°C

Working

pressure

bar

670

780

890

1000

1110

1220

1330

1440

1550

1660

130

150

180

200

0,4

Combustion

chamber

load loss

∆p mbar

104

118

132

146

160

174

187

Combustion

chamber

volume

Water

load

losses

0,5

0,8

1,8

2,2

2,6

3,2

4,5

∆t20

2,8

3,4

4,8

6,5

8,5

∆t 10

310

361

412

463

514

565

616

670

725

780

Weight

of unit

kg.

Model

GN2 05

GN2 06

GN2 07

GN2 08

GN2 09

GN2 10

GN2 11

GN2 12

GN2 13

GN2 14

Model

GN2 05

GN2 06

GN2 07

GN2 08

GN2 09

GN2 10

GN2 11

GN2 12

GN2 13

GN2 14

128,8

153,3

177,7

202,2

226,6

251,1

275,5

300

324,4

348,8

Heat and

D.H.W.

(gross)

gas

Max.

116

138

160

182

204

226

248

270

292

314

Heat and

D.H.W.

(net)

gas+oil

Max.

88,8

100

122,2

138,8

155,5

172,2

188,8

205,5

222,2

238,8

Heat and

D.H.W.

(gross)

gas

Min.

110

125

140

155

170

185

200

215

Heat and

D.H.W.

(net)

gas+oil

Min.

101

115

129

143

157

171

185

199

Potenza

termica

Min.

105

125

145

165

185

205

225

245

265

285

Heat and

D.H.W.

output

N°

element

105

113

121

Water

capacity

505

615

725

835

945

1055

1165

1275

1385

1495

Combustion

chamber

lenght

400

Combustion

chamber

dimension

Ømm

GN2

Fig. 4

1. Boiler unit

5. Accessory kit

2. Shell

3. Control panel

4. Elements

Boiler GN2 can be supplied in two versions, with the

boiler unit either assembled or in parts.

Three packs will be dispatched in the first case:

1. Boiler unit

2. Shell

3. Control panel

In the second case, there will be the following 4 packs:

2. Shell

3. Control panel

4. Kit of parts forming the boiler unit

5. Kit of accessories with which to mount the elements.

3. Packing and dispatch (fig. 4)

6GN2

4.01 (Fig. 5) Use a 12 mm strip of wood to shim the rear

element.

Now rest it on a second strip, checking that it remains

stable throughout the assembly operations.

4. Boiler assembly

Fig. 5

Fig. 6

Fig. 7

4.03(Fig.7) Using the tin in the assembly kit, spread

a thin layer of minium on the link and its housing,

using a soft brush.

Fig. 8

4.04 (Fig. 8) Mount the link in its housing, tapping lightly

with a wooden mallet.

4.02(Fig.6) Use fineglasspapertothoroughlycleanthe

housing of the link on the rear element and of all other

elements forming the boiler unit.

Boiler unit

GN2

Fig. 10

Fig. 11

Fig. 12

Fig. 9

4.05(Fig.9)Usingthetubeofsiliconeintheassemblykit,

spread a small amount of this product in the retention

seal housing.

4.06 (Fig. 10) Near the first intermediate element to the

rear element.

8GN2

ROD GN2 12 ELEM. LG. TOT. 1290

ROD GN2 14 ELEM. LG. TOT. 1510

Fig. 16

Fig. 13

4.07 (Figs 11 - 12 - 13) Insert rod 1 between the two

elements, mount nut 3 on the threaded end, place stop

pin 2 ontheholeoftherodnearthepairofelementsthen

clamp the unit together using a N°4 wrenchuntil the

two elements have been perfectly joined together.

4.08 Proceed as described in the previous paragraph

until all the elements forming the boiler unit have been

mounted.

Fig. 14

4.09 (Figs 14 - 15 - 16) Mount the four rods «1», the

Belleville washers «2» as shown in fig. 15 and finally

torque nuts «3».

Fig. 15

Mounting the rods with the Belleville washers.

NOTE: The Belleville washers must be mounted in an

opposed way as shown in the diagram while the nuts

must be fixed in order to prevent them from being

crushed.

For GN2 boilers with 12 - 13 - 14 elements, mount the

rods with sleeve part 1, remembering to fully tighten the

sleeve thread on both sides.

GN2

Fig. 17

Fig. 19

Fig. 20

4.10 (Fig. 17) Using the relative pump, connect to

coupling 1 and pump in water under pressure (8 bar).

Wait a few minutes before checking that thereareno

leaks. Now check that smoke retention between the

elements is correct.

IndustrieFER S.r.l.declinesallresponsibilityfordamage

to persons or property caused by water or smoke leaks

from the boiler due to incorrect assembly or failure to

check retention.

Fig. 18

- Mount the following parts ontherearsideoftheboiler:

- four stud bolts (1)

- eight stud bolts (2) with their relative flanges (3) and

seals (4)

- Mount the collar (5) with the screws (6) and spread a

small amount ofsilicone(includedinthekit)aroundthe

retention seal housing on the rear end.

4.11 (Fig. 19) Mount all parts on the front side as shown

in the diagram.

4.12 (Fig. 20) Assembly detail of the servicing door and

burner hatch.

10 GN2

4.13 (Fig. 21) Cover the boiler unit with the supplied mineral wool insulation.

4.14 (Fig.22) Theboiler unitcan alsobe suppliedalready assembled.It willbesentstraightfromthefactoryonapallet.

Remove bolts 1 fixing the boiler to the pallet and place the boiler itself in its final installation position. Now proceed by

mounting the various panels.

Fig. 21

Fig. 22

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