GN Boiler range

15kW - 650kW floor standing cast iron range of boilers

10 year manufacturers guarantee on the cast iron

GN Boiler range
15kW - 650kW floor standing cast iron range of boilers
FERRO LI
EN303 PIN TYPE App No

Boiler installation requirements

Ferroli Spa Via Rito Sab B C97,02 G07 CE0085 AS05 1QGDX 8 217 8 02863 9 330316 9 128

Thank you for choosing Ferroli. This manual provides important information on safety of operation, installation & maintenance, and is an integral and essential part of the product. Please read this manual before installation, it will be required for future reference. This data must be diplayed on the appliance Our preferred position being - right hand side, front, top. If not displayed guarantee will be invalid. Please note: If you have not received your data plate or you have mislaid it please contact Ferroli Commercial for a duplicate Immediately.

Serial N o 000000 Heat in 000 put kW Heat ou tput k

GN4 N 07

The Ferroli GN Boiler range

Ferroli boilers are manufactured from high quality cast iron and are designed for a reliable long life with a 10-year manufacturers guarantee on the cast iron work. Subject to commissioning by Ferroli, there is also a 2-year manufacturers guarantee on parts and labour. All GN models are suitable for natural gas, LPG or oil-fired pressure jet burners, with a duel fuel option. The models in the GN range are: GN1 GN2 GN4 23.3 kW to 93 kW 90 kW to 252 kW 200 kW to 650 kW body is insulated with high density mineral fibre to minimise heat loss from the heat exchanger. GN1 and GN2 models have a double-pass heat exchanger, whilst the GN4 has a triple-pass heat exchanger for maximum heat transfer and ultra-high operating efficiency. The GN range is designed for use with fully pumped indirect systems operating at working pressures up to 6bar at 90C flow temperature. The pre-wired control panel is housed in a stylish casing and incorporates: on/off illuminated switches; high/low thermostatic control with limit thermostat (manual re-set); and a temperature and pressure gauge. The boilers are designed with front access for ease of maintenance and the clearance required at the side of the boiler is kept to a minimum. This makes the GN models particularly suitable for modular installations. The Ferroli Enerstep Stage 9 high performance sequence controller is specifically designed for use with Ferroli boilers in the commercial heating and venting market. It gives significant efficiency improvements that can give major fuels savings on cast iron boilers. The system comprises: a plug-in main control unit supported by ancillary control elements; temperature sensors to give weather compensation, optimum start, night set back and frost protection; and interface modules etc that allow almost any specification of boiler sequence control mode to be supplied. The Enerstep Stage 9 will control up to 18 boilers with full optimum start facility which will provide inside and outside weather compensation.

The GN range is a highly efficient boiler with on/off, high/low or modulating burner operation. We can also supply pre-mix burners which are fully modulating, low nox and quiet. The individual sections have been developed to achieve the highest boiler efficiency in order to reduce fuel consumption. The boiler

400 . .

a1

1"

GN1

Q 850 542 270 B 1" a2 a3 80 711

Boiler control panel Key 1. Blank socket 2. Thermometer / pressure gauge 3. High limit stat manual reset 4. Main switch 5. Control thermostat
1

Boiler Model GN1

No sections Boiler output (High Fire)kW Boiler output ( Low Fire) kW Boiler input (gross) (High Fire) kW Boiler input (gross) (Low Fire) kW Boiler input(nett) Gas/ Oil (High Fire) kW Boiler Input (nett) Gas/ Oil (Low Fire)kW Water content litres Design flow rates @ t 11C litres/sec Waterside pressure drops @ t 11C mb Design flow rates @ t 20C litres/s Waterside pressure drops @ 20Ct mb Maximum water pressure bar Minimum static head m Minimum flow rate litres/s Input gas rate (High Fire) m3 Working pressure boiler nat gas mb Max gas inlet pressure boiler nat gas mb Burner pressure Approx flue gas volume @ 9% CO2 @ NTP m3/h Approx flue gas temp nett (primary flue) C Gas inlet connection Water flow/return connections a1 & a2 ins Drain cock a3 ins Draught required @ boiler flue outlet mb pascal Flue connection nominal dia mm Electrical supply 230 v 50Hz single phase Combustion chamber length mm Boiler length A mm Blast tube diameter B mm Flue diameter Q mm Pressure drop load loss t p mb Combustion chamber volume litres Water load loss t 10C t 20C Weight kg Water content litres Front clearance min mm Rear clearance min mm Side clearance min mm MAXIMUM WATER FLOW TEMPERATURE 90 C MINIMUM RETURN TEMP 45C 02 23.3 15.0 28.6 18.2 25.8 16.4 11 0.51 1.0 0.28 6 2.1 0.2 2.18 20 25 56.3 220 1 1/2 3/ 4 0.02 2 130 Yes 286 300 105 130 0.2 12.09 1 75 11 750 800 50 03 34.9 15.0 43.0 18.2 38.7 16.4 14 0.76 1.8 0.42 6 2.1 0.3 3.26 20 25 87.25 220 1 1/2 3/ 4 0.02 2 130 Yes 386 400 105 130 0.2 20.15 1.8 100 14 750 800 50 04 05 06 46.5 58.1 69.8 32.5 40.5 48.8 57.3 71.6 86.1 39.3 49.1 59.1 51.6 64.5 77.5 35.4 44.2 53.2 17 20 23 1.01 1.26 1.52 4.2 7.2 11.0 0.55 0.69 0.83 1.0 1.6 2.3 6 6 6 2.1 2.1 2.1 0.4 0.5 0.6 4.35 5.42 6.52 20 20 20 25 25 25 as per burner manufactures data 117.5 136.1 182.7 220 220 220 as per burner manufacturer data 1 1/2 1 1/2 1 1/2 3/ 3/ 3/ 4 4 4 0.02 0.02 0.02 2 2 2 130 180 180 Yes Yes Yes 486 586 686 500 600 700 105 105 125 130 180 180 0.02 0.2 0.2 28.21 36.27 52.39 4.2 7.2 11 1 1.6 2.3 125 150 175 17 20 23 750 750 750 800 800 800 50 50 50 07 81.4 57.0 100.4 68.8 90.4 62.0 26 1.76 15.0 0.97 3.3 6 2.1 0.7 7.60 20 25 213.7 220 1 1/2 3/ 4 0.02 2 180 Yes 786 800 125 180 0.2 60.45 15 3.3 200 26 750 800 50 08 93.0 65.0 114.7 78.6 103.3 70.8 29 2.01 20.0 1.1 4.5 6 2.1 0.8 8.69 20 25 248.7 220 1 1/2 3/ 4 0.02 2 180 Yes 886 900 125 180 0.2 68.51 20 4.5 225 29 750 800 50

600

a1

GN2

1196

867 Q

375

726

B A1 Central heating flow DN80 3" A2 Central heating return DN80 3" A3 Boiler drain 3/4" 84

a2

a3

Boiler control panel Key 1. Blank socket 2. Thermometer / pressure gauge 3. High limit stat manual reset 4. Main switch 5. Control thermostat
1

Boiler Model GN2

No sections Boiler Output High Fire kW Boiler Output ( Low Fire) kW Boiler Input (gross) High fire gas + oil kW Boiler Input (gross) Low fire gas + oil kW Water Content litres Design flow rate @ t11C litres/sec Waterside Pressure loss @ 11Ct mb Design flow rate @ 20Ct litres /s Waterside Pressure loss @ 20Ct mb Maximum water pressure bar Minimum Static head m Minimum flow rate litres/s Input Gas Rate High Fire m3 Working pressure boiler Nat gas mb Max gas inlet gas pressure mb Draught required @ boiler flue outlet mb pascal Burner pressure Approx flue gas volume @ NTP m3 Approx flue gas temp C Boiler flue gas resistance mb Electrical supply 230 v 50Hz Combustion chamber pressure drop p mb Combustion chamber volume litres Boiler length A mm Blast tube diameter B mm Flue diameter Q mm Water flow/return connections a1, a2, ND 80 Drain cock a3 ins Gas Inlet connection Weight kg Front clearance min mm Rear clearance min mm Side clearance min mm MAXIMUM WATER FLOW TEMPERATURE 90 C MINIMUM RETURN TEMP 45C 05 90 73 98.8 80 49 1.95 2.8 1.07 6 2.1 0.72 13 20 25 0.02 2 140 220 0.3 Yes 0.4 63 647 130 180 3 3/4 310 1000 800 200 06 108 87 117.4 95 57 2.35 3.4 1.29 6 2.1 0.86 15 20 25 0.02 2 159 220 0.31 Yes 0.4 77 757 130 180 3 3/4 361 1000 800 200 07 126 101 136.9 110 65 2.74 4.8 1.50 0.5 6 2.1 1.0 17 20 25 0.02 2 196 220 0.32 Yes 0.4 91 867 130 200 3 3/4 412 1000 800 200 08 144 115 156.5 125 73 3.13 6.5 1.72 0.8 6 2.1 1.15 20 20 25 0.02 2 218 220 0.33 Yes 0.4 104 977 154 200 3 3/4 463 1000 800 200 09 10 11 12 162 180 198 216 129 143 157 171 176.0 195.6 215.2 234.7 140 155 170 185 81 89 97 105 3.52 3.91 4.3 4.7 8.5 11 13 16 1.93 2.15 2.36 2.58 1.8 2.2 2.6 3.2 6 6 6 6 2.1 2.1 2.1 2.1 1.29 1.43 1.58 1.72 22 24 27 29 20 20 20 20 25 25 0.02 0.02 0.02 0.02 2 2 2 2 as per burner manufacturers data 247 273 305 326 220 220 220 220 0.34 0.36 0.37 0.38 Yes Yes yES Yes 0.4 0.4 0.4 0.4 118 132 146 160 1087 1197 1307 1417 154 154 154 154 200 200 200 200 3 3 3 3 3/4 3/4 3/4 3/4 as per burner manufacturers data 514 565 616 670 1000 1000 800 800 200 200 13 234 185 254.3 200 113 5.01 19 2.79 4.0 6 2.1 1.86 32 20 25 0.02 2 370 220 0.39 Yes 0.4 174 1527 154 200 3 3/4 725 1000 800 200 14 252 199 273.9 215 121 5.47 23 3.00 4.5 6 2.1 2.0 33 20 25 0.02 2 402 220 0.40 Yes 0.4 187 1637 154 200 3 3/4 780 1000 800 200

850

A B1

B2 A1

GN4

1193

Q 542 463 B A2

Selection of flow and return connections

For boiler changeover projects and particularly those older systems with high water volumes operating with t up to 30oC then the options to use flow (B1) and top return (B2) may be considered. For traditional systems operating on a t of 11oC then top flow (A1) and bottom return (A2) may be used although it is a mandatory requirement that a shunt pump is fitted and it is recommended that for circulation purposes a flow equivalent to t 25oC is applied. Any shunt pump must be proved running before the boiler fires.

Boiler control panel Key 1. Blank socket 2. Thermometer / pressure gauge 3. High limit stat manual reset 4. Main switch 5. Control thermostat
1

Minimum flow rate @ t 25oC

Boiler model Duty l/s 07 1.9 08 09 10 11 12 13 14 6.2 2.37 2.84 3.41 3.99 4.55 5.3

Boiler Model GN4

No sections Boiler Output High Fire kW Boiler Output ( Low Fire) kW Boiler Input (gross) High fire gas + oil kW Boiler Input (gross) Low fire gas + oil kW Water Content litres Design flow rate @ 11Ct litres/sec Waterside Pressure loss @ 11Ct mb Design flow rates @ 20Ct litres/sec Waterside Pressure loss @ 20Ct mb Maximum water pressure bar Minimum Static head m Minimum flow rate litres/s Input Gas Rate High Fire m3 Working pressure boiler Nat gas mb Max gas inlet gas pressure mb Burner pressure Approx flue gas temperature Net temperature (primary flue)C Approx flue gas volume @ 9% Co2 @ NTP m3/h Draught required @ boiler flue outlet mb pascal Water flow/return connections A1,A2,B1,B2. ND 80 weld Gas Inlet connection Electrical supply 230 v 50Hz Combustion chamber length mm dia Boiler length A mm Flue diameter Q mm Pressure drop load loss p mb Combustion chamber volume litres Weight kg Water content litres Front clearance min mm Rear clearance min mm Side clearance min mm MAXIMUM WATER FLOW TEMPERATURE 90 C MINIMUM RETURN TEMP 45C 07 200 120 217 128 143 4.32 66 2.58 20 6 2.1 1.73 20.28 20 25 200 318 0.02 2 3" Yes 880 500 1040 180 0.5 161.3 940 143 1000 800 200 08 250 150 270 160 163 5.39 99 2.7 30 6 2.1 2.16 25.23 20 25 200 393 0.02 2 3" Yes 1010 500 1170 180 0.8 185.1 1050 163 1000 800 200 09 10 11 12 300 360 420 480 180 215 250 290 324 388 452 516 192 229 266 309 183 203 223 243 6.46 7.75 9.08 10.4 139 178 215 254 3.3 3.87 4.53 5.17 42 54 65 77 6 6 6 6 2.1 2.1 2.1 2.1 2.6 3.6 3.12 4.16 30.28 36.26 42.24 48.22 20 20 20 20 25 25 25 25 as per burner manufacturers data 200 200 200 200 468 558 646 734 0.02 0.02 0.02 0.02 2 2 2 2 3" 3" 3" 3" as per burner manufacturers data Yes Yes Yes Yes 1140 1270 1400 1530 500 500 500 500 1300 1430 1560 1690 250 250 250 250 0.7 1.0 1.4 1.7 208.9 232.8 256.6 280.4 1170 1270 1400 1510 183 203 223 243 1000 1000 1000 1000 800 800 800 800 200 200 200 200 13 560 330 600 352 263 12.1 292 6.03 88 6 2.1 4.85 56.07 20 25 200 848 0.02 2 3" Yes 1660 500 1820 250 2.6 304.3 1630 263 1000 800 200 14 650 390 695 416 283 14.1 331 7.0 100 6 2.1 5.63 64.95 20 25 200 977 0.02 2 3" Yes 1790 500 195 250 3.5 328.1 1740 283 1000 800 200

Appliance & installation design

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

British Standards
BS 3456, Part 201: Electrical standards. BS EN 60335, Part 1: Safety of household & similar electrical appliances. BS 5925: Ventilation principles and design for natural ventilation. BS 5440; Part 1, Part 2 Installation & maintenance of flues. BS 6644: Installation of gas fired hot water boilers 60kW to 2mW. BS 6700: Design, installation, testing and maintenance of services supplying water for domestic use. BS6891: Installation of low-pressure gas pipe-work of up to 28 mm in domestic premises. BS 7074: Application selection and installation of expansion vessels and ancillary equipment for sealed hot water systems Part 2: Code of practice for medium temperature hot water systems. BS 7593: Flushing of systems. CP 342: Centralised hot water supply. Part 2: Buildings other than dwellings.

commercial gas Installations. IGE/UP/1A/ Edition 2. Tightness testing and purging of small industrial and commercial gas Installations. IGE/UP/2 Edition 2. Gas installation pipework, boosters and compressors in industrial and commercial premises. IGE/UP/4. Commissioning of gas fired plant industrial and commercial premises. IGE/UP/10/ Edition 2. Installation of gas appliances in industrial and commercial premises. Part 1: flued appliances.

Water systems modular installations

Flow and return headers should be connected in a "reverse return" arrangement, (water flow in each header flows the same direction) providing equal flow through each boiler. This ensures the pressure loss across any number of boilers will never be greater than the header loss across one boiler plus the associated pipework of the header (See System Layout Page). Care should be taken during the initial stages of design and layout to take into consideration adequate water flow through the boiler, and the influence of system controls. Control valves and system controls, when fitted, should be regulated to avoid lower flows occurring. The minimum recommended flow at any time corresponds to a 22C temperature rise across the boiler. A minimum return temperature of 45C should be maintained.

Other publications
Gas Safety Regulations 1998. Building Regulations Parts F and J.

Boiler siting
The boiler should be positioned on a level, non-combustible surface that can adequately support its weight when full of water and connected to ancillary equipment. Suitable clearances are required for access, servicing and maintenance see dimensions and layout.

Institute of Gas Engineers & Managers Publications

IGE/UP/1/Edition 2. Tightness testing and purging of industrial and

Boiler 60kW 60 kW 150kW

Open Vent Size Cold Vent Size 25mm (1") 32mm (11/4") 19mm (3/4") 25mm (1") 32mm (11/4") 38mm (11/2")

150 kW 300kW 38mm ( 11/2") 300 kW 600kW 50mm (2")

Sealed systems, pressure relief valves

Each boiler, or in a modular installation each bank of boilers, must be fitted with a pressure relief valve to BS 759 or BS 6759 Part 1 and sized as shown in BS 6644. BS 6644 provides the necessary information for the selection and location of safety valves and attention is drawn to the higher capacity requirements of safety valves for pressurised hot water systems.
Example 1 Reverse return header arrangement.

System head open vented systems

The minimum system static head is to be no less than 2.1m. An independent cold feed and expansion pipes are to be installed in accordance with BS 6644: Section 2 Item 10. For single and multiple boiler installations, they will not be smaller than shown in the table above. The minimum head must be increased if necessary to comply with minimum head specified by the pump manufacturers in order to avoid cavitation.

Commissioning
Ferroli recommends that all boilers are commissioned by its own engineers. On completion, a commission and emission form and Ferroli benchmark book will be issued to record any maintenance and service work. There is a two-year parts and labour warranty on the boiler/burner when the boiler is commissioned by Ferroli.

Water treatment for hot water boilers.

Irrrespective of the water characteristics, unless the initial fill water from the mains is treated there will always be corrosion within a heating or hot water system. Water in a closed system will also promote corrosion unless treated. Ferroli strongly recommends that, where necessary, the system should be flushed hot and cold with proprietary cleaner before the use of a stable inhibitor that will not require topping up to combat the effects of hardness EVOPLATE salts and corrosion on the heat exchangerReduced hot water storage up to 75% of the boiler and associated system. Specialist water treatment less then a traditional storage calorifier. suppliers, such as Sentinel or Fernox, will adviseLightweight with minimumand on all treatment issues footprint. dosage requirements.maximum should Achieve the Flushing possible be in accordance with the performance from condensing boiler requirements of BS: 7593.
installations. Reduced downtime and maintenance. Integral dual action domestic water ensuring constant flow through the exchanger and reducing the risk

Boiler primary pump

Heating pump

Boiler 1

Boiler 2

Boiler 3

Boiler 4 Heating load

Return Common header

Example 2 Combined heating & domestic hot water with diverter valve on DHW and Mixing vavle on heating.
Sequence controller 1 2 3 Boiler primary pump Water sensor Boiler 1 Boiler 2 Boiler 3 Flow Mixing valve Heating pump Return Common header Heating load

Diverter valve

Typical Low Loss Header

Boiler Flow pump Connection

Bypass

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

Sequence controller 1 2 3 Boiler primary pump Water sensor Boiler 1 Boiler 2 Boiler 3 Mixing valve Flow

from legionnaires Flow disease.

Connection

Compensator Mixing valve Zone pump Compensator Zone pump Heating zone 1

Min distance between flow and return connection 600mm

Min length of header 1000mm Return Connection

Heating zone 2

Return Common header

Boiler Return Connection

2 balanced header

Air supply and ventilation

Air supply and ventilation
An adequate supply of fresh air and ventilation for combustion and cooling must be provided in accordance with BS 6644. The air supply must be free from contamination to avoid unnecessary cleaning and servicing of the boilers. I All ventilation provision should be at high & low level, direct to outside air, and where possible on the same elevation. I Where air is supplied by mechanical means into a boiler/plant room, air in should be by mechanical inlet and air outlet by natural ventilation (boiler/plant room under positive pressure) and interlocked. I Where mechanical inlet and outlet systems are applied, the design ventilation flow rates should be as per Table 4 of BS. 6644. IGE/UP/10 Part 1 Edition 2 section 7.2 I Where a boiler/plant room is below ground level, low-level ventilation should be ducted to loe level, terminating 300mm above floor level of the burner level. I Safety shut down for mechanical ventilation systems should be provided to cause safety shutdown or lockout of the boiler(s) in the event of air flow failure in either inlet or outlet ventilation ducts. I These openings must be fitted with grills that cannot be blocked or flooded. Fans should be selected to always create a positive pressure in the boiler house relative to outside air pressure. Air supplied for boiler house ventilation should be such that the maximum temperatures within the boiler house are: At floor level (100mm above floor level) At mid level (or 1.5m above floor level) 25C 32C

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

Ventilation requirements of hot water boilers (BS 6644)

Boiler input gas rate 60 kW 2 MW 60kW 2 MW Position of air vent High Level Low Level Where to Outside Air Outside Air Air vent free area requirement Total Input kW 60kW x 2.25cm = ? + 270cm = High level ventilation requirement Total Input kW 60kW x 4.5cm = ? + 540cm = Low level ventilation requirement

Ferroli easy guide to ventilation calculations

For example: 3 boilers in plant room of 217 kw input gas rate each = 651 kW total High level Low level 651 60 = 591 x 2.25 =1329.75 +270 =1599.75cm2 651 60 = 591 x 4.5 = 2659.50 +540 0 =3199.50cm2 Free Ventilation Requirement 1599.75cm2 3199.50cm2

Gas supply
Type of fitting 20mm 25mm 40mm 50mm 65mm 80mm 100mm Per elbow 0.5 0.5 1.0 1.5 2.0 2.5 3.5 Per tee 0.5 0.5 1.0 1.5 2.0 2.5 3.5 Per 90 bend 0.3 0.3 0.3 0.5 0.5 1.0 1.5 The gas supply must be installed by a competent person, and in accordance with BS 6891, IGE/UP/2 edition 2, tested to IGE/UP/1 and IGE/UP/1A edition 2. All pipework must be of adequate size and the pressure loss from the meter to point of use should not exceed 1mb. The following table gives pipe lengths from a gas meter to point of use with 1mb pressure loss for natural gas end to end. The table must be used in conjunction with losses of various fittings shown in the table above.

Input Maximum length of gas pipe (from Meter) gas rate 20mm 25mm 32mm 40mm 50mm 80mm 2.67 28.6 10.5 39 4.1 43 5 20 57 5.4 57.3 12 32 81 306 6.7 71.6 8 74 56 211 8.1 86.1 17 40 155 1040 9.3 100.4 31 119 800 10.7 114.7 28 109 734 11.7 125 20 81 552 14 150 59 405 16.35 175 51 345 18.7 200 36 246 23.4 250 27 187 28.1 300 17 122 32.7 350 13 94 37.4 400 10 74 42 450 8 60 46.7 500 7 50 51.4 550 6 42 56.07 600 36 65.42 700 27

M3/hr

For example: 100mm Boilers with a total input of 100kW with 8 elbows can have a maximum length of 19m of 50 mm pipe. Less (8x1.5m) = 107m of pipe run with 1mb pressure loss. The tables are based on IGE/UP/2 Edition 2, the information is provided for guidance only. All flow rates are in straight horizontal pipes with 1mb differential between ends. We have assumed a metered supply at 21mb and a maximum of 1mb pressure loss for natural gas to point of use.

1567 1340 959 730 478 366 291 237 197 167 143 110

Servicing and Maintenance

Servicing
Ferroli will not accept any liability resulting from the use of unauthorised parts or the repair and servicing of appliances not carried out in accordance with the companys recommendations and specifications. A comprehensive service of the appliance should be carried out at least once a year by a CORGI registered installer, and in accordance with current Gas Safety Regulations. Warning: Always switch off the gas supply at the nearest isolation valve and switch of and isolate/disconnect the electrical supply to the appliance, before commencing any work on the appliance.

Initial Lighting
1. Check the electrical supply is turned off. 2. Check that all drain cocks are closed, that any stop valves fitted to the flow and return pipes are open and that the system has been filled and vented correctly. Ensure there are no visible signs of leakage. 3. Check the gas supply has been tested and purged in accordance with relevant gas 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 to 50% of its scale.

The burner should light at the end of its ignition period, if not the lockout will be illuminated. Press in and release the lockout button on the control box. The controls will be reset and return to ignition sequence. Once the burner has come to full fire the burner on light will appear. When the burner has lit check connections with LDF. Set boiler thermostat to required setting. Once the burner is in operation you should refer to the burner manufacturers set instructions for the correct commissioning of the burner to the Ferroli boiler. In all cases we advise individual manufacturers to commission and setup burners to individual requirements..

10

Servicing and Maintenance

Spillage checks
Spillage and flue flow tests must be carried out to ensure there is no spillage of combustion products from the boiler in accordance with BS 5440:1.

Water flow rates through boiler

When commissioning the heating and domestic hot water system, the shunt pump or primary boiler pump should be adjusted to give the minimum flow rate as per the table when only part of the system is in operation for the dissipation of residual heat.

Explain why the correct ventilation is required, and the safe operation of the flue. Hand the installation and servicing instructions, users instructions and log book to the customer/responsible person and request they are kept in a safe place and readily available when remedial/maintenance work is carried out. IMPORTANT INFORMATION

Testing
Check that the burner responds correctly to manual on/off operation of any controls fitted in the gas control circuit. Check the operation of the flame failure safety device. 1. Extinguish the main burner/pilot by turning off the main gas inlet valve. 2. The controls will go to lockout immediately and the lockout light will illuminate. 3. Turn gas valve on, and press the reset button in and release the lockout button. After a period of time the controls reset and the burner will re-light. 4. Complete the commissioning section of the boiler logbook.

Hand over
Full instructions covering routine lighting and operation of the boiler and burner are given in the lighting and operation instructions. These should be located adjacent to the boiler. A practical demonstration of lighting and shutdown of the boiler/burner should be given to to the owner or responsible person. You should give a full description of the function of boiler/burner and system controls, and how they are adjusted and operated.

Regular maintenance and servicing must be carried out at a maximum of 1 year intervals in order to ensure reliable and efficient operation. Regular maintenance will prolong the life of the boiler/burner. After completion of service and maintenance work the logbook should be brought up to date and retained for further reference. All work should be carried out by a CORGI registered engineer in accordance with current gas safety regulations.

11

Flue systems

GN boilers are designed for use with natural draught flues. Flue systems should be designed in accordance with current regulations. The boiler is designed for connection to a single flue system with one boiler, or a common flue header in the case of a multi boiler installation. The flue system should be designed to maintain atmospheric pressure with slight suction at the boiler flue connection at all times. If the suction is to exceed 0.0 mb we would recommend the fitting of a draught stabiliser to the flue system.

The flue system must be selfsupporting; access for cleaning is required along with maintenance joints or similar close to the boiler connection to allow removal of flue box during servicing. The design of the flue system must ensure that any condensate which may be formed within the system can be safely drained to a suitable disposal point and the flue material used is resistant to the corrosive effects of the condensate. GN boilers are suited to installation in balanced compartments in accordance with the requirements of BS 6644.

Ferroli is aware that flue package systems are available from various manufacturers who offer comprehensive range of flue and chimney equipment for natural draught, fan-assisted and fan dilution applications. They will provide you with a full design and installation service, to incorporate sizing, site survey and approved drawings prior to installation.

12

Ferroli Pump Selection Chart

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

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

Pump Model UPS 15-60 UPS25-55 UPS25-55 UPS 25-55 UPS 25-55 UPS 25-55 UPS32-55 UPS32-55 UPS32-55 UPS32-55

Pipe Size 1" 11/4" 11/4" 11/4" 11/4" 11/4" 11/2" 11/2" 11/2" 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 Size GN4N 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 40-30 GN4N 12* 480 kW 10.39 l/s 77 mbar 4.16 l/s UPS 50-30 GN4N 13* 560 kW 12.12 l/s 88 mbar 4.85 l/s UPS 50-30 GN4N 14* 650 kW 14.07 l/s 100 mbar 5.63 l/s UPS 65-30 *Denotes flanged pump

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Electricals

Wiring external to the boiler must be installed in accordance with the I.E.E. regulations and any local regulations that apply. Wiring must be completed in heat resistant cable. For wiring size refer to the technical instructions supplied by the burner manufacturer. The boiler control panel requires a 230V, single phase 50Hz supply. Fuse ratings for individual boilers are marked on the appliance date plate. The control panel is supplied with flying lead and plugs for direct connection to a corresponding socket supplied on the burner. Should a non-standard burner be fitted to the boiler the manufacturer must provide Ferroli with a satisfactory wiring diagram to suit its boiler wiring diagram. Responsibility for suitable connections is at the risk of the third party. The method of connection to the mains electrical supply must

facilitate complete isolation of the single boiler or bank of boilers with a contact separation of at least 3mm in all poles. The appliance must be isolated from the mains electrical supply in the event of electric arc welding being carried out on any connecting pipework. The mains isolator must be located adjacent to the boiler in a readilyaccessible position. The supply should only serve one boiler. Note: Volt-free contact electrical supplies must also be isolated where fitted. Further details regarding connection to electricity supply are given in BS EN 60335 Pt.1 or BS 3456 Pt. 201. Volt-free contacts are normally to the burner. You are requested to check with burner manufacturers for suitability of connection to your control system.

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Ferroli Limited 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 Europe, employing over 2,500 people and producing a wide range of wall hung, cast iron and welded steel boilers, making Ferroli one of the largest and most successful heating appliance manufacturers in the world. Ferroli Domestic Heating Offering gas wall mounted units with outputs from 5kW to 50kW, Ferrolis stylish, compact domestic boilers provide maximum comfort with minimal fuel usage. With a choice of conventional, condensing and combi technologies, theres a boiler to match the heating and hot water requirements of every home. In recent years Ferroli has also become a Northern European leader in solar heating, and has developed underfloor heating systems for the UK market. Ferroli Commercial and Industrial Heating, Tel: 08707 282 755 Ferroli commercial boilers for pressure jet oil, forced air gas or dual-fuel are factory matched with high efficiency 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 as stainless steel unvented hot water cylinders, pressurisation units and plate heat exchangers. We are also taking a lead in developing underfloor and solar heating solutions. Ferroli Service, Tel: 08707 282 755 Once the normal guarantee period on our boilers has expired, coverage can be extended cost-effectively with a choice of Ferroli service contracts to suit your budget. All Ferroli service engineers work to Benchmark standards and the Benchmark Code of Practice for the installation, commissioning and servicing of central heating systems, designed to improve the quality of work undertaken by plumbers and heating installers. Ferroli Spares, Tel: 08707 282 885 The rapidly growing popularity of Ferroli as first choice for both domestic and commercial installations means that heating parts stockists offer readily available spares for Ferroli boilers. For less frequently needed items, we maintain a fully-stocked warehouse located centrally in the UK, enabling same-day despatch of just about any part needed to keep your Ferroli boiler running at optimum efficiency. Ferroli Training, Tel: 08707 282 891 Ferroli understands that well-trained installers are the key to a safe and efficient heating system. Thats why we run comprehensive training courses in our purpose-built facilities for everyone concerned in the installation and servicing of Ferrolis range of boilers. These courses improve installers knowledge and skills by providing both the theory and the hands-on practical experience essential to maintaining heating system performance and safety.

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

Ferroli Ltd Lichfield Road Branston Industrial Estate Burton-Upon-Trent Staffordshire DE14 3HD tel 08707 282 882 fax 08707 282 883 e-mail: domestic@ferroli.co.uk www.ferroli.co.uk
All the information in this guide was correct at the time of printing. Specifications and designs may be changed due to Ferrolis policy of continuous product research and development. The statutory right of the consumer are not affected. August 2006.