Ferroli GN 3 Installation And Use Instructions Manual

Brand: Ferroli

Model: GN 3

Category: Power heat guns

Type: Installation And Use Instructions Manual

Ferroli GN 3 is a new highly efficient heat generator. It is a cast iron boiler assembled with double steel cones and rods. The boiler can operate either with liquid and/or gas-fuelled burners. The boiler shell consists of cast iron elements assembled with double steel cones and rods.

The boiler is able to produce hot water for central heating purposes and domestic hot water. The water content ranges from 116 to 225 dm3, and the maximum working pressure is 4 bar. The boiler has a high efficiency, with gross heat outputs ranging from 181.1 to 593.3 kW and net heat outputs ranging from 163 to 534 kW.

HIGH EFFICIENCY

CAST IRON BOILER

FOR LIQUID

and/or GAS FUELS

INSTALLATION

AND USE INSTRUCTIONS

GN 3

GN3

Thank you for having purchased a Ferroli boiler.

Your new GN3 has been built according to highly advanced technologies using strong and reliable materials.

Please follow our advice carefully and you will certainly get the best from your boiler. Ferroli quality also covers the

technical and functional features of the boiler which comply with the current provisions in merit.

Amongst the documents in the package supplied with this appliance, you will find:

* Instruction manual

* Certificate of Guarantee

Please comply with our instructions to ensure correct installation. The “CERTIFICATE OF GUARANTEE” should be

filled out withyour address and forwarded toFerroli for endorsement.

Our company runs a network of After-Sales Service Centers to ensure prompt assistance throughout the home territory.

Thanking you once again for your preference, please remember that we are at your complete disposal for any further

information you may require.

Best regards.

FERROLI

Industrie Riscaldamento S.p.A.

TABLE OF CONTENTS

General information ....................................................................................................................................... page 3

Features ........................................................................................................................................................ page 4

Installation ..................................................................................................................................................... page 8

Assembling the boiler shell ............................................................................................................................ page 10

Assembling the casing .................................................................................................................................. page 17

Inspections .................................................................................................................................................... page 23

Adjustements ................................................................................................................................................ page 23

Servicing ....................................................................................................................................................... page 24

GN3

GENERAL INFORMATION

Description

Boiler GN3 is a new highly efficient heat generator. It

produces hot water for heating purposes and is able to

operate with either liquid and/or gas fuelled burners.

The boiler shell consists of cast iron elements assembled

with double steel cones and rods. The shape has been

specially designed for optimum fin distribution in order to

achieve high thermal efficiency with consequently excel-

lent enery savings.

Together with the dry chamber, the shape of the shell

enables this appliance to operate with delivery tempera-

tures of about 60°C without the formation of condensate.

Boiler insulation consists of a thick layer of mineral wool

which reduces heat dispersion in the environment to the

minimum.

Packing (fig. 2)

Boiler GN3 can be supplied in two types of pack: with the

boiler shell assembled or in parts:

In the former case, 3 packs will be sent including:

1. Boiler body

2. Casing

3. Control panel

In the latter case, there will be 4 packs containing:

2. Casing

3. Control panel

4. Group of elements

5. Accessory kit

1. Boiler body

2. Casing

3. Control panel

4. Group of elements

5. Accessory kit

Fig. 1

Fig. 2

Burner inhibition warning light

Electronic plant (not supplied)

Boiler thermometer

Burner switch and warning light

2nd burner stage operation

hour counter

Safety thermostat

2nd burner stage adjuster thermostat

1st burner stage adjuster

thermostat

1st burner stage operation

hour counter

GN3

Technical brief (fig. 3)

FEATURES

Fig. 3

Key

1. Electronic plant (optional)

2. 1st burner stage operation hour counter

3. 2nd burner stage operation hour counter

4. Burner inhibition warning light

5. Boiler thermometer

6. Safety thermostat

7. Burner switch and warning light

8. 2nd burner stage adjuster thermostat

9. 1st burner stage adjuster thermostat

10. Pressure tap connection in combustion chamber

11. Porthole to inspect the flame

a1. Flow C.H. ND 80 - 3" Gas

a2. Return C.H. ND 80 - 3" Gas

250

11 10

6215789

855

88.5

690

437

1278

850

1180

193

Model

GN3 06

GN3 07

GN3 08

GN3 09

GN3 10

GN3 11

GN3 12

GN3 13

GN3 14

Model

GN3 06

GN3 07

GN3 08

GN3 09

GN3 10

GN3 11

GN3 12

GN3 13

GN3 14

116

130

144

158

172

186

197

211

225

Water

content

Elements

n°

150

175

200

225

250

275

300

325

350

Min.

163

190

217

244

271

298

325

352

379

Min.

181.1

211.1

241.1

271.1

301.1

331.1

361.1

391.1

421.1

Min.

Heat and D.H.W.

(Output)

Heat and D.H.W.

(Net) (Gas+Oil)

Heat and D.H.W.

(Gross) (Gas)

Working

pressure

bar

780

890

1000

1110

1220

1330

1440

1550

1660

113

120

145

170

195

220

245

270

297

Combustion

chamber

volume

0.93

1.20

1.45

1.80

2.00

2.50

3.00

3.60

4.60

Pressure

combustion

chamber

∆p mbar

668

756

852

948

1044

1140

1236

1332

1428

Shell

weight

kg.

Water

load

loss

100

105

110

∆p 15 mbar

255.5

297.7

340

382.2

424.4

466.6

508.8

551.1

593.3

Max.

230

268

306

344

382

420

458

496

534

Max.

210

245

280

315

350

385

420

455

490

Max.

GN3

Boiler shell (fig. 4)

Fig. 4

26d 37401650 COMP.CYLINDER FOR COMB.CHAMBER - 9 elem.

26e 37401660 COMP.CYLINDER FOR COMB.CHAMBER -10 elem.

26f 37401660 COMP.CYLINDER FOR COMB.CHAMBER -11 elem.

26g 37401670 COMP.CYLINDER FOR COMB.CHAMBER -12 elem.

26h 37401670 COMP.CYLINDER FOR COMB.CHAMBER -13 elem.

26i 37401670 COMP.CYLINDER FOR COMB.CHAMBER -14 elem.

27 35315970 COMBUSTION CHAM.INSULATION

28 33202020 UPPER BOILER DOOR FN.

29 35315980 UPPER DOOR INSULATION

30 38008700 COMPLETE UPPER DOOR

31 38008820 COMPLETE BURNER DOOR

32 37511420 COMPLETE DOOR HANDLE

33 35002220 HANDLE 3P 110/B 6111090 M16

34 33202041 BOILER BURNER DOOR FN.

35 35315961 BURNER DOOR INSULATION D.586 THICKNESS 67

36 35316090 INNER DOOR INSUL. Ø 586 THICKNESS 6.4

37 32152530 FLANGE D.340 THICKNESS 12

38 35352910 CERAMIC FIBER SEAL D.340

40 34008850 PORTHOLE FLANGE 105x61 THICKNESS 8

41 33700860 SEAL 105x61 TH.2 FLANGE

43 33400280 VENT 1/6 WITH SMOOTH SEAL HOLDER

44 35352930 MICA DISK D.44 THICKNESS 0.5

45 34008940 PIN 12x50 UNI 1713

47 A0 38445240 WATER DISTRIBUTION PIPE FRONT SECTION

47 A1 38445230 WATER DISTRIBUTION PIPE FRONT SECTION

47 A2 38445220 WATER DISTRIBUTION PIPE FRONT SECTION

47 B3 38445250 WATER DISTRIBUTION PIPE REAR SECTION

47 B4 38445260 WATER DISTRIBUTION PIPE REAR SECTION

47 C2 34223560 WATER DISTRIBUTION PIPE MIDDLE SECTION

48 35100180 RUBBER SEAL ED 133 ID 90 TH.4

49 34008861 FLANGE C. 160x160 THICKNESS 16

54 34300320 SPRING CLIP

1 33004552 FRONT ELEMENT FN.

2 33004570 INTERMEDIATE ELEMENT FN.

2a 33004910 INTERMEDIATE ELEMENT (LOW HEIGHTS) FN.

3 33004580 INTERMEDIATE ELEMENT WITH LEGS FN.

4 33004560 REAR ELEMENT FN.

5 34205080 94.4 ED DOUBLE CONE 100.22 LG.45

6a 34403380 ROD M16x 780 THREAD 80/80 - 6 elem.

6b 34403390 ROD M16x 910 THREAD 80/80 - 7 elem.

6c 34403400 ROD M16x1040 THREAD 80/80 - 8 elem.

6d 34403410 ROD M16x1170 THREAD 80/80 - 9 elem.

6e 34403420 ROD M16x1300 THREAD 80/80 -10 elem.

6f 34403430 ROD M16x1430 THREAD 80/80 -11 elem.

6g 34403440 ROD M16x1580 THREAD 80/80 -12 elem.

6h 34403450 ROD M16x1690 THREAD 80/80 -13 elem.

6i 34403460 ROD M16x1820 THREAD 80/80 -14 elem.

7 34504940 SPRING MDE 34x16.3x2 DIN 2093

8 34504930 LONG NUT M16 UNI 5587

9 33400811 SHEATH 1"1/4x235 (6 BULBS)

10 34007500 HEX PLUG DA 11/4

11 34505080 THREADED BAR 12x100

12 34505050 THREADED BAR M12x80

13 34503360 STUD BOLT M16x75 THREAD 25/25

14 34503120 STUD BOLT M16x65 THREAD 25/25

16 34008970 PIN M16x135 FOR HANDLE

17 33202001 LOWER BOILER DOOR HINGE

18 34008990 PIN M12x37 TO FIX HINGE

19 34010370 CYLINDER LOCKING PIN

20 34010420 FUMES CHAMBER COLLAR FN.

21 33100790 BOILER FUMES CHAMBER FN.

22 33100810 FUMES CHAMBER HATCH FN.

23 34504430 STUD BOLT M10x50 THREAD 20/20

26a 37401640 COMP.CYLINDER FOR COMB.CHAMBER - 6 elem.

26b 37401640 COMP.CYLINDER FOR COMB.CHAMBER - 7 elem.

26c 37401650 COMP.CYLINDER FOR COMB.CHAMBER - 8 elem.

GN3

Casing (fig. 5)

61 37025080 COMPL.RIGHT FRONT SIDE UNIT

62 37025090 COMPL.LEFT FRONT SIDE UNIT

63 37025100 COMPL.COMPON.SIDE UNIT TYPE 1 (6-9-13 elem)

64 37025110 COMPL.COMPON.SIDE UNIT TYPE 2 (6-9-10-11-13-14 elem.)

65 37025120 COMPL.COMPON SIDE UNIT TYPE 3 (7-11-12 elem.)

66 31000210 STUD COUPLING CLIP

67 31207470 SIDE FIXING BRACKET

68 31132780 CASING SUPPORT PLATE

69 37025160 COMPL.UPPER FRONT PANEL

70 34000640 STUD FOR COUPLING

73 37025170 COMPL.LOWER FRONT PANEL

74 36500200 RUBBER CORE HITCH ART. 302 OVA

75 37025130 COMPL.COMPON.COVER TYPE 1 (6-9-13 elem.)

76 37025140 COMPL.COMPON.COVER TYPE 2 (6-9-10-11-13-14 elem.)

77 37025150 COMPL.COMPON.COVER TYPE 3 (7-11-12 elem.)

78 31134530 COMPLETE REAR WALL

79 38503630 FERROLI TYPE DOUBLE CORE HITCH

80 38200860 COMPLETE INSTRUMENT PANEL

81 38701280 COMPLETE KNOB FOR THERMOSTAT

82 36401210 PROBE TR2 540499 C.1500 PVC 3CNT

83 36401450 PROBE LS 541577 C.1500 PVC 110°C

84 36450010 CIRC.THERMOM.0-120°C CAP.1000

85 34100442 PERFORATED HINGE 25x24 TH.1.2

86 31207520 WIRING SUPPORT PLATE

87 35001091 DARK BROWN SCREEN-PRINTED PLUG 96x144

98 36100200 SWITCH UP.SPL60 ART. 6000.8.05

89 36200390 RED WARNING LIGHT SPL80 ART. 6029.2.00

90 36504800 CLOCK ART. FWZ-55 220v-50HZ

91 38504852 WIRING CONTROL PANEL

Fig. 5

GN3

Wiring diagram (fig. 6) Load loss diagram (fig. 7)

Fig. 6

BOILER Amm Bmm Cmm Dmm

GN3.06 600 618 520 98

GN3.07 600 618 520 98

GN3.08 750 785 520 115

GN3.09 750 785 520 115

GN3.10 950 1000 650 130

GN3.11 950 1000 650 130

GN3.12 1200 1280 650 160

GN3.13 1200 1280 650 160

GN3.14 1200 1280 650 160

Fig. 8

Key

TR1 1st burner stage adjuster thermostat

TR2 2nd burner stage adjuster thermostat

IB Burner switch

STB Safety thermostat

BZ1 1st stage burner hour counter

BZ2 2nd stage burner hour counter

B Burner plant panel

SB Burner safety warning light

Fig. 7

Fumes route (fig. 8)

GN3

INSTALLATION

The boiler must only be installed by qualified Personnel,

in compliance with the Manufacturer’s instructions and all

the Laws and provisions which govern the matter.

Particular attention should be paid to safety Provisions

and those which govern the construction and location of

flues.

Base (fig. 9)

GN3 is a boiler which does not require a special base.

Just prepare a simple plinth which can be reinforced if

necessary, in order to facilitate boiler positioning. In some

cases, particular installations may require a special

soundproofed base.

Boiler positioning (fig. 10)

When building the base check, after boiler assembly with

the

burner on the front door, that this latter can open without

the burner hitting against the wall or any other boiler in the

vicinity. Leave a free space of at least 100 mm from the

part towards which the door swings.

A free space should also be left in front of the boiler. This

space should equal the length of the boiler itself and allow

the cylinder to be removed from the combustion cham-

ber.

Burner

Electrical connection

Only qualified Personnel should complete the electrical

connections of the boiler and control panel or the burner

and plant connections.

Always connect the boiler to a good grounding system.

FERROLI S.p.A. declines all responsibility for damages

to persons and/or property caused by failure to connect

the appliance to a good grounding system.

Hydraulic connection

The hydraulic connections of the boiler should be accom-

plished in compliance with the indications given near

each union and those included in the Technical Brief.

Connection must be carried out so that the pipes are free

from tensions. It is obligatory to mount the safety valve on

the heating circuit, as near as possible to the boiler but

without any obstruction or on-off device between the

boiler itself and the valve. Valve setting should be 3 bar.

The appliance is not supplied with expansion tank.

Connection of this latter shall therefore be at the Installe-

r’s charge. Remember that pressure in the system when

cold, must be between 0.5 and 1 bar.

ELEMEN. A mm L mm

GN3.06 780 1010

GN3.07 910 1140

GN3.08 1040 1270

GN3.09 1170 1400

GN3.10 1300 1530

GN3.11 1430 1660

GN3.12 1560 1790

GN3.13 1690 1920

GN3.14 1820 2050

Normal base

Soundproofed base

Fig. 10

Fig. 9

Burner

GN3

Heating plant installation (fig. 11).

If there is a boiler recirculating pump, it is obligatory to

mount non-return valves upstream of the return union to

prevent parasitic circulations in the generators.

The recirculation flow rate must be between:

P P

and

5 45

P = Capacity of each boiler expressed in kcal/h

Burner operation must be linked to that of the recircula-

tion pump. It must only operate if the pump operates. As

an accessory, a flow rate monitoring device in series with

thermostat TH can be mounted on the return pipe leading

to the boiler, downstream of the recirculating pump.

Flue connection

Always connect the boiler to a good flue, built in complian-

ce with the current provisions in force. The duct between

the boiler and flue must be made of suitable material, i.e.

able to withstand the temperature and corrosion. Always

check the seal in the jointing points and thermally insulate

the entire pipeline between the boiler and stack, to

prevent the formation of condensation.

Fig. 11

GN3

ASSEMBLY

Element assembly layout (fig. 12)

MOD. FRONT INT. ELEMENT INT. ELEMENT INT. ELEMENT REAR ELEMENT

ELEMENT WITH SH. FINS WITH LEGS

COD.3300455/2 COD. 3300491/0 COD. 3300458/0 COD. 3300457/0 COD. 3300456/0

GN3 06 11 3 1

GN3 07 12 3 1

GN3 08 1213 1

GN3 09 1214 1

GN3 10 1314 1

GN3 11 1315 1

GN3 12 1316 1

GN3 13 1317 1

GN3 14 1318 1

Fig. 12

GN3

Boiler shell

2. (Fig. 14) Clean the link housing with grease solvent.

Thoroughly clean the twin-cone housing on the rear

element using fine glass paper, then clean all the other

elements forming the boiler shell, if there is rust.

4. (Fig. 16) Mount the twin-cone in its housing, lightly

tapping it into place with a wooden mallet.

Fig. 13

Fig. 14

Fig. 15

3. (Fig. 15) Clean the links with grease solvent. Using the

package in the assembly kit, spread a light coating of

minium on the twin-cone and its housing, using a soft

brush.

Fig. 16

1. (Fig. 13) Use a 15 mm. wooden strip to shim the rear

element.

Now set a second strip in place, checking that it remains

stable throughout the assembly operations.

GN3

5. (Fig. 17) Using the packet of silicone included in the

assembly kit, spread a light strip of this product in the

retention seal housing (on both sides of the intermediate

element).

6. (Fig. 18) Starting from point A, mount the retention seal

in its housing.

7. (Fig. 19) Comply with the indicated route until comple-

ting this in point B.

Fig. 17

Fig. 19

Fig. 18

GN3

9. (Figs 21-22-23) Insert rod 1 through the two elements.

Mount nut 3 on the threaded end. Place stop pin 2 on the

rod hole near to the breadth of the two elements. Using

a 4 wrench, tighten the unit until the two elements have

been perfectly joined.

Fig. 20

Fig. 21

Fig. 22

Fig. 23

8. (Fig. 20) Place the first intermediate element near the

rear one, after having prepared it as described for the rear

element itself (points 3 - 4 - 5 - 6 and 7). Also add the

retention seal from point C through to point D.

GN3

Fig. 24

Fig. 26

as to crush them.

13. (Fig. 26) Mount the following parts on the front side of

the boiler shell:

* Four stud bolts 1 (M12x80) of the upper door.

* Two stud bolts 2 (M12x135) of the door closing handw-

heels.

* Door support 3, fixing it with the two screws 4.

Place the cylinder (6) in the combustion chamber

according the indications in fig. 8 (complying with

dimension in table) insert the pin in the cylinder hole.

14. (Fig. 27) Mount distribution pipe 1, if necessary in

parts interspaced with a seal 2.

Check that the notch on the flange points upwards so that

the water through holes are pointing downwards. Mount

the second seal 2, flange 3, washers 4 and then tighten

with nuts 5.

10. Proceed as described in the previous paragraph until

all the elements forming the boiler shell have been

mounted.

11. (Fig. 24-25) Mount the four rods “1”, the six Belleville

washers “2” in the rear part of the boiler shell, then tighten

nuts “3”.

12. (Fig. 24) Mount the following parts on the rear side of

the boiler shell:

* Three stud bolts 4 (M12x100) of the smokebox.

* Four stud bolts 5 (M16x65) of the upper flange.

* Four stud bolts 6 (M16x75) of the lower flange.

Mounting the rods with the Belleville washers (fig. 25)

NOTE: The springs must be mounted opposite, as shown

in the drawing, and the nuts must not be fixed so strongly

Fig. 25

Fig. 27

GN3

1035

902

769

1833

1700

1567

1434

1301

1168

GN3.06

GN3.07

GN3.08

GN3.09

GN3.10

GN3.11

GN3.12

GN3.13

GN3.14

447

490.0

SECTION A0 A1 A2 C2 B3 B4 Spring Clip

PART. Nr.3844524/0 3844523/0 3844522/0 3422356/0 3844525/0 3844526/0 3430032/0

GN3.06 1 1 1

GN3.07 1 1 1

GN3.08 1 1 1 2

GN3.09 1 1 1 2

GN3.10 1 2 1 3

GN3.11 1 2 1 3

GN3.12 1 3 1 4

GN3.13 1 3 1 4

GN3.14 1 4 1 5

Set of 8 spring clips: part. N° 3980273/0

Composition Water Distribution Pipe

Fig. 27a

Spring clip

HOLE

Example for GN3.09

A1 = Flange section

with 1 hole

C2 = Middle section

with 2 holes

B4 = End section

with 4 holes

GN3

16. (Fig. 29) Mount flange 1 after having interspaced seal

2, washers 3. Now tighten with nuts 4.

18. (Fig. 31) Mount the upper front door on the four stud

bolts 1 and lock it in place with the relative nuts 2.

Fig. 29

Fig. 31

17. (Fig. 30) Mount the smokebox on the three stud bolts

4 (Fig. 24), locking them in place with nuts 3.

15. (Fig. 28) Using the relative pump, connect to union 1

and let water under pressure into the boiler (8 bar). Wait

a few minutes before checking that there are no leaks.

Now check that the fumes seal between the elements is

correct.

Ferroli S.p.A. declines all responsibility for damage to

persons or property caused by fumes and water leaks

from the boiler due to assembly errors or negligent seal

inspections.

Fig. 28

Fig. 30

GN3

22. (Fig. 35) The boiler shell can be supplied already

assembled. In this case, it will be dispatched from the

factory on a pallet.

Remove bolts 1 fixing it to the pallet and place it in its

permanent installation position. Now mount the various

panels.

20. (Fig. 33) Fix the door with knobs 7 which should be

screwed on to stud bolts 2 (Fig. 26) and with knobs 8

already fitted with stud bolts.

CASING ASSEMBLY

19. (Fig. 32) Mount the lower door of the burner, hinging

it to support 3 (Fig. 28) with the relative pins 1 and split

pins 2.

Fig. 32

Fig. 33

21. (Fig. 34) Cover the boiler shell with the supplied sheet

of mineral wool, fixing it to rods 1 (Fig. 24) and using clips

7 included in the assembly kit.

Fig. 34

Fig. 35

GN3

24. (Fig. 37) Prepare the right and left side panels,

choosing the number of panels according to the size of

the boiler.

22 a. (Fig. 35a) Mount rear panel 1 of the smokebox, on

the three stud bolts without fixing it.

Fig. 35a

23. (Fig. 36) Mount bar 2 on upper rods 1 (Fig. 24) and fix

it with nuts 3.

ABCDE

6 elem. 910 536 — — —

7 elem. 1040 666 — — —

8 elem. 1186 812 406 406 —

9 elem. 1316 942 406 536 —

10 elem. 1446 1072 536 536 —

11 elem. 1576 1202 666 536 —

12 elem. 1706 1332 666 666 —

13 elem. 1852 536 536 536 406

14 elem. 1982 1608 536 536 536

Fig. 37

13-14 element. 8-12 element. 5-7 element.

GN3

25. (Fig. 38) Connect the panels together using screws 1,

washers 2 and nuts 3, reinforcing their lower part with

bars 4 fixed with screws 5.

26. (Fig. 38) Slacken knobs 8 on the right side of the boiler

together with the two screws 4 fixing door support 3.

27. (Fig. 40) Insert the complete right side panel between

door support 3 and the boiler shell, checking that the

machined slots fit into their correct positions.

Now tighten screws 4 and knobs 8.

Fig. 39

Fig. 40

Fig. 38

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Ferroli GN 3 Installation And Use Instructions Manual

Brand: Ferroli

Model: GN 3

Category: Power heat guns

Type: Installation And Use Instructions Manual

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Ferroli GN 3 Installation And Use Instructions Manual

Ferroli GN 3 Installation And Use Instructions Manual

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