FG
,
cod. 3540I950 — 06/2007 (Rev. 00)
INSTRUCTIONS FOR USE, INSTALLATION AND MAINTENANCE INSTRUCTIONS D'UTILISATION, D'INSTALLATION ET D'ENTRETIEN KULLANMA, KURULUM VE BAKøM TALIMATLARø
FG
B• Carefully read the warnings in this instruction booklet since they provide important information on safe installation, use and maintenance.
•This instruction booklet is an integral part of the product and must be carefully kept by the user for future reference.
•If the unit is sold or transferred to another owner or if it is to be moved, always make sure that the booklet accompanies the boiler so that it can be consulted by the new owner and/or installer.
•Installation and maintenance must be carried out by professionally qualified personnel, according to current regulations and the manufacturer's instructions.
•Incorrect installation or poor maintenance can cause damage or physical injury. The manufacturer declines any responsibility for damage caused by errors in installation and use or by failure to follow the manufacturer's instructions.
•Before carrying out any cleaning or maintenance operation, disconnect the unit from the electrical power supply using the switch and/or the special cut-off devices.
•In case the unit breaks down and/or functions poorly, deactivate it, do not make any attempt to repair it or directly intervene. Contact professionally qualified personnel. Any repair/replacement of products must only be carried out by qualified professional personnel using exclusively genuine parts. Failure to comply with the above could affect the safety of the unit.
•Periodical maintenance carried out by qualified personnel is essential for guaranteeing good operation of the unit.
•This unit must only be used for the purpose for which it was designed. Any other use is considered improper and therefore hazardous.
•After removing the packing, check the integrity of the contents. Packing materials must not be left within the reach of children as they are potentially hazardous.
•In case of doubt do not use the unit, and contact the supplier.
•The images shown in this manual are a simplified representation of the product. In this representation there may be slight, unimportant differences with the supplied product.
BThis symbol indicates "Caution" and is placed next to all safety warnings. Strictly follow these instructions in order to avoid danger and damage to persons, animals and things.
AThis symbols calls attention to a note or important notice.
Declaration of conformity
Manufacturer: FERROLI S.p.A.
Address: Via Ritonda 78/a 37047 San Bonifacio VR Italy declares that this unit complies with the following EU directives:
•Low Voltage Directive 73/23 (amended by 93/68)
•Electromagnetic Compatibility Directive 89/336 (amended by 93/68)
President and Legal Representative
Cav. del Lavoro
Dante Ferroli
2 |
- |
06/2007 |
GB |
cod. 3540I950 |
(Rev. 00) |
FG
1 Operating instructions ............................................................................................................ |
4 |
|
1.1 |
Introduction............................................................................................................................................. |
4 |
1.2 |
Control panel .......................................................................................................................................... |
4 |
1.3 |
Lighting and shutdown ........................................................................................................................... |
5 |
1.4 |
Adjustments............................................................................................................................................ |
6 |
2 Installation................................................................................................................................ |
8 |
|
2.1 |
General Instructions ............................................................................................................................... |
8 |
2.2 |
Place of installation ................................................................................................................................ |
8 |
2.3 |
Plumbing connections ............................................................................................................................ |
8 |
2.4 |
Safety coil connection (optional) ............................................................................................................ |
9 |
2.5 |
Electrical connections........................................................................................................................... |
10 |
2.6 |
Connection to the flue .......................................................................................................................... |
11 |
3 Service and maintenance...................................................................................................... |
12 |
|
3.1 |
Adjustments.......................................................................................................................................... |
12 |
3.2 |
Startup.................................................................................................................................................. |
12 |
3.3 |
Maintenance......................................................................................................................................... |
12 |
3.4 |
Troubleshooting.................................................................................................................................... |
14 |
4 Technical data and characteristics ...................................................................................... |
15 |
|
4.1 |
Dimensions, connections and main components ................................................................................. |
15 |
4.2 |
Pressure loss........................................................................................................................................ |
16 |
4.3 |
Technical data table ............................................................................................................................. |
16 |
4.4 |
Wiring diagram ..................................................................................................................................... |
17 |
, |
cod. 3540I950 - 06/2007 (Rev. 00) |
|
3 |
FG
1.Operating instructions
1.1Introduction
Dear Customer,
Thank you for choosing a FERROLI boiler featuring advanced design, cutting-edge technology, high reliability and quality construction. Please read this manual carefully since it provides important information on safe installation, use and maintenance.
FG is a wood-burning steel boiler, with total gasification. It exploits the principle of reverse flame combustion, with gradual burning of the wood, to the advantage long operation times before refuelling. In fact, thanks to a variable-speed fan located at the back of the boiler, combustion occurs in a negative pressure. the lit wood, placed in a holder above a special grill, develops a particular type of combustion which, thanks to the high temperature determined by a balanced supply of primary combustion air from above and secondary air injected through the separation grill, turns the cellulose into simpler compounds that burn in the underlying combustion chamber with a flame similar to that of natural gas, with efficiencies exceeding 85%. In the wood loading stage the fan is activated when the door is opened, thus preventing smoke from escaping.
The outer casing consists of painted steel panels, insulated internally with mineral wood to ensure optimum insulation of the boiler body. A safety exchanger for eliminating the excess heat can be installed by request.
1.2 Control panel
fig. 1 - Control panel
Key
1 |
Control panel |
6 |
Button M, Summer/Winter "Mode" changeover |
2 |
Wood loading door |
7 |
Parameter editing + - buttons |
3 |
Combustion chamber/ash compartment door |
8 |
Button R, configuration menu access |
4 |
Combustion air adjustment |
9 |
Display |
5 |
Heating temperature adjustment + - buttons |
10 |
Lighting switch |
During operation, the display shows the system delivery temperature.
4 |
- |
06/2007 |
GB |
cod. 3540I950 |
(Rev. 00) |
FG
1.3 Lighting and shutdown
Fuel
The boiler must only operate with normal and untreated wood. The logs can be 50 cm long for models FG30 and FG40, and 70 cm for model FG50. Pressed fuels and briquettes can also be used, provided they are entirely of wood.
BThe burning of waste, plastic or liquids can create dangerous burnt gases with risk of poisoning, death or explosion.
•Only use the specified fuels.
•In the presence of risk of explosion, fire, burnt gases or fumes, put the boiler out of service.
•The boiler must only be operated by adults who are familiar with the boiler instructions and its operation.
•The user is only authorised to start the boiler, set the heating temperature, put it out of service and clean it.
•Keep unsupervised children away from the boiler when it is operating.
•Do not burn liquids or use them to increase boiler performance.
•Only use non-flammable agents to clean the surface of the boiler.
•Do not place flammable objects on or near the boiler.
•Do not place flammable materials in the boiler installation compartment (e.g. wood, paper, petroleum, gas oil).
Wood is an extremely heterogeneous fuel for type, moisture content, shape and size. Boiler heating efficiency depends on the type of wood used and its moisture content, as well as the method of loading and size of the fuel. Excellent quality woods are oak, ash, beech, maple and fruit trees except cherry; chestnut and birch are good quality; lime, poplar and willow are of adequate quality. Resiniferous woods are generally mediocre fuels. The higher the moisture-content, the lower the heating power. The use of fuels that are not dry causes losses of efficiency. Use logs dried outdoors and in the natural state (stored for 2 years with max. moisture content 20%).
Boiler lighting
•Open the bottom door and remove any ash present in the combustion chamber. Close the bottom door.
•Switch on the power to the unit. Turn the switch to ON.
•Open the top door. Place some paper and kindling on the burner plate.
•Light the fuel and add some slightly larger pieces of wood.
•Close the door and wait for a first bed of embers to form.
•Open the top door slowly to allow the fan to suck the smoke accumulated in the firewood holder.
•Spread the embers evenly on the burner plate, using a poker.
•Load wood when the bed of embers has formed on the main stone.
Loading wood
•Proceed with loading wood which must be 50 cm long for models FG30 and FG40, and approx. 70 cm for model FG50.
•Since regular falling of the wood is essential for good combustion, make sure that the length of the pieces of wood introduced, their shape and method of loading do not hinder it. The pieces must be arranged lengthwise and horizontally. No pieces must be inclined or placed sideways.
•Consume the wood as much as possible before loading more.
•New loading can be carried out when the bed of embers in the holder is approx. 5 cm deep.
•Open the top loading door slowly.
•Arrange the new load of wood in the same way as previously described.
B- Pieces that are too long do not fall regularly, causing empty spaces in the wood holder, with the formation of unburnt wood areas.
-Pieces that are too short cause uneven air passages, with a decrease in power and efficiency.
-Always open the top door slowly, in order to avoid puffs and the creation of smoke.
-Never open the bottom door during operation.
-During loading avoid keeping the top door open for long periods.
-In case of operation with reduced performance, low temperature distilled gases can form, with risk of poisoning if breathed.
-If dense smoke can be seen, do not breathe it.
-Make sure the installation room is well-ventilated.
-Clean the boiler and gas exhaust ducts as prescribed.
GB |
- |
06/2007 |
5 |
cod. 3540I950 |
(Rev. 00) |
FG
Boiler shutdown
To shut down the boiler, allow all the fuel to be burned.
Shutdown for short periods
For short shutdown periods, turn the lighting switch to OFF after the fuel has finished and the boiler has cooled.
•Clean the loading door support surfaces and the loading compartment.
•Remove the ashes and clean the combustion chamber.
•Close the ash compartment door and the loading door.
Shutdown for long periods
To put the boiler out of service for long periods (e.g. at the end of the cold season), carefully clean the boiler to prevent corrosion.
BTo avoid damage caused by freezing during long idle periods in winter, it is advisable to drain all water from the boiler, or add a suitable antifreeze to the heating system, in compliance with that prescribed in sec. 2.3.
1.4Adjustments
Summer/Winter changeover
Press the button 
to activate Summer/Winter changeover.
Heating temperature setting
Operate the buttons
and
(detail 5 fig. 1) to set the system delivery temperature.
The control system regulates the fan air delivery and therefore the speed of combustion for reaching and maintaining the set temperature.
BAt too low boiler water temperatures tar forms inside the boiler, and at temperatures below 65 °C condensate forms in the combustion chamber.
Frequent operation below 65 °C causes a big reduction in the boiler's useful life. Make sure the boiler water temperature remains constantly between 80 - 90 °C.
6 |
- |
06/2007 |
GB |
cod. 3540I950 |
(Rev. 00) |
FG
Secondary air adjustment
The smoke extractor fan located on the back of the boiler supplies the primary combustion air. The boiler is equipped with a factory-set secondary air adjustment device, which must be checked with the aid of a combustion analyser in the first lighting stage. The adjustment screw can subsequently be used to adapt the supply of secondary air according to the quality and type of fuel.
fig. 2 - Secondary air adjustment
AOpen
BClosed
•Large, wet are hard to burn wood: close 1 notch.
•Dry and very flammable wood: open 1 notch or more.
•If the boiler tends to puff due to very wet fuel, close it gradually.
System pressure adjustment
Periodically check that the system is full of water. These checks must be carried out cold, checking the expansion tanks (open types must have water at the initial level, whereas in closed types the pressure must be equal to or higher than the initial prefilling pressure).
GB |
- |
06/2007 |
7 |
cod. 3540I950 |
(Rev. 00) |
FG
2.Installation
2.1General Instructions
BOILER INSTALLATION MUST ONLY BE PERFORMED BY QUALIFIED PERSONNEL, IN ACCORDANCE WITH ALL THE INSTRUCTIONS GIVEN IN THIS TECHNICAL MANUAL, THE PROVISIONS OF CURRENT LAW, THE PRESCRIPTIONS OF NATIONAL AND LOCAL STANDARDS AND THE RULES OF PROPER WORKMANSHIP.
2.2 Place of installation
The boiler must be installed in a special room with ventilation openings towards the outside in conformity with current regulations. If there are several burners or extractors that can work together in the same room, the ventilation openings must be sized for simultaneous operation of all the units. The place of installation must be free of flammable objects or materials, corrosive gases, volatile substances or dusts that can be sucked by the fan. The room must be dry and not exposed to rain, snow or frost.
AEnsure enough space around the unit for removing the casing and for normal servicing operations. In particular, make sure there is enough space in the front part of the boiler for loading the fuel.
2.3Plumbing connections
The heating capacity of the unit must be previously established by calculating the building's heat requirement according to current regulations. The system must be provided with all the components for correct and regular operation. It is advisable to install on-off valves between the boiler and heating system allowing the boiler to be isolated from the system if necessary.
BThe safety valve outlet must be connected to a funnel or collection pipe to prevent water spurting onto the floor in case of overpressure in the heating circuit. Otherwise, if the drain valve is activated and floods the room, the boiler manufacturer cannot be held liable.
Do not use the water system pipes to earth electrical appliances.
Before installation, carefully wash all the pipes of the system to remove residuals or impurities that could affect correct operation of the unit.
Carry out the relevant connections according to the diagram in cap. 4 "Technical data and characteristics" and the symbols given on the unit.
Characteristics of the water system
In the presence of water harder than 25° Fr (1°F = 10ppm CaCO3), use suitably treated water in order to avoid possible scaling in the boiler. Treatment must not reduce the hardness to values below 15°F (Decree 236/88 for uses of water intended for human consumption). Treatment of the water used is indispensable in case of very large systems or with frequent introduction of replenishing water in the system.
Antifreeze system, antifreeze fluids, additives and inhibitors
If necessary, antifreeze fluids, additives and inhibitors can be used only if the manufacturer of these products guarantees that they are suitable for this use and do not cause damage to the boiler exchanger or other components and/or materials of the unit and system. Do not use antifreeze fluids, additives or inhibitors that are not specific for use in heating systems and not compatible with the boiler materials and system.
8 |
- |
06/2007 |
GB |
cod. 3540I950 |
(Rev. 00) |
FG
2.4 Safety coil connection (optional)
An external (cooling circuit) safety heat exchanger (optional) can be supplied together with the boiler.
In countries where Standard EN 303-5 is applied, the boiler must have a system enabling a safety outlet for the excess heat without additional energy. In this way the maximum boiler water temperature will not exceed 100 °C (overheating protection).
The minimum cooling water supply pressure must be 2.0 bar. A flowrate of at least 10 l/min. must be available.
•Remove the flange “A” located at the back of the boiler.
•Install the coil “N”, fixing it with the 4 bolts.
•Fit the safety valve "P" on the outlet of the coil "N", respecting the direction of the arrow. Insert the valve probe "Q" in the special sheath "G". Connect the water inlet directly to the safety coil. Connect the valve outlet.
fig. 3 - Safety heat exchanger connection
GB |
- |
06/2007 |
9 |
cod. 3540I950 |
(Rev. 00) |
FG
2.5 Electrical connections
Fitting the control panel
1.Remove the control panel cover "P" by undoing the two side screws "V".
2.Arrange the cables of the fan "B", the sensor "A" and the door microswitch "C" as shown in fig. 4
3.Connect the fan cable to the terminal block, respecting the colours indicated in fig. 5 and fix the condenser"R" with the special adhesive clamp.
4.Connect the cable of the microswitch "C" to the terminals as shown in fig. 5.
5.Insert the probe "A" in the special pocket.
fig. 4 - Fitting the control panel
R |
34 |
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296 |
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16 |
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14 |
13 12 |
11 |
10 |
9 |
8 |
7 |
6 |
5 |
4 |
3 |
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Giallo/Verde |
Blu |
Nero/Bianco |
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fig. 5 - Connection to the terminal block
C Condenser 16 Fan
34 Heating temperature sensor
296 Door microswitch
10 |
- 06/2007 |
GB |
cod. 3540I950 |
(Rev. 00) |
FG
Connection to the electrical grid
BThe unit's electrical safety is only guaranteed when correctly connected to an efficient earthing system executed according to current safety standards. Have the efficiency and suitability of the earthing system checked by professionally qualified personnel. The manufacturer is not responsible for any damage caused by failure to earth the system. Also make sure that the electrical system is adequate for the maximum power absorbed by the unit, as specified on the boiler dataplate.
The boiler is prewired and provided with a Y-cable and plug for connection to the electricity line. The connections to the grid must be made with a permanent connection and equipped with a bipolar switch whose contacts have a minimum opening of at least 3 mm, interposing fuses of max. 3A between the boiler and the line. It is important to respect the polarities (LINE: brown wire / NEUTRAL: blue wire / EARTH: yellow-green wire) in making connections to the electrical line. During installation or when changing the power cable, the earth wire must be left 2 cm longer than the others.
BThe user must never change the unit's power cable. If the cable gets damaged, switch off the unit and have it changed solely by professionally qualified personnel. If changing the electric power cable, use solely “HAR H05 VV-F” 3x0.75 mm2 cable with a maximum outside diameter of 8 mm.
2.6Connection to the flue
The unit must be connected to a flue designed and built in compliance with current regulations. The pipe between the boiler and flue must be made from material suitable for the purpose, i.e. heat and corrosion resistant. Ensure the seal at the joints and insulate the entire pipe between boiler and flue, to prevent the formation of condensate.
GB |
- 06/2007 |
11 |
cod. 3540I950 |
(Rev. 00) |
FG
3. Service and maintenance
All adjustment, conversion, startup and periodical checking operations described below must only be carried out by Qualified Personnel (meeting the professional technical requirements prescribed by current regulations).
FERROLI declines any liability for damage and/or injury caused by unqualified and unauthorised people tampering with the unit.
3.1 Adjustments
Secondary air adjustment
During the startup stage it is advisable to check the setting of the secondary air adjustment device.
Light the boiler and carry out first loading with the same type of fuel to be used by the end-user.
Wait for the boiler to stabilise.
Using a combustion analyser check the CO in the fumes. If the CO content is > 0.5% gradually open the regulator until obtaining a CO value of < 0.5%.
N.B.: opening the secondary air regulator of the boiler too much can result in uneven combustion (tendency to "puff"). In this case close the regulator by 1/2 - 1 notch.
3.2 Startup
BChecks to be made at first lighting, and after all maintenance operations that involved disconnecting from the systems or operations on safety devices or parts of the boiler.
Before lighting the boiler
•Open any on-off valves between the boiler and the systems.
•Check correct prefilling of the expansion tank
•Fill the water system and make sure that all air contained in the boiler and the system has been vented.
•Make sure there are no water leaks in the system, connections or boiler.
•Check correct connection of the electrical system and efficiency of the earthing system
•Make sure there are no flammable liquids or materials in the immediate vicinity of the boiler
Checks during operation
•Turn the unit on as described in sec. 1.3.
•Check the seal of the water systems.
•Check the efficiency of the flue and air-fume ducts while the boiler is working.
•Check that the water is circulating properly between the boiler and the systems.
•Check the seal of the wood loading and combustion chamber doors.
•Check combustion and correct setting of the secondary air control device.
3.3 Maintenance
Warnings
B- Before carrying out any maintenance make sure to disconnect the power to the boiler and wait until it is at room temperature.
-Never drain (even partially) the water from the system, unless absolutely necessary.
-Do not clean the boiler and/or its parts with easily flammable substances (e.g. petrol, alcohol, etc.).
-Do not leave containers with flammable substances in the room where the boiler is installed.
-Do not clean the heating system with boiler operating.
- Use tube brushes and vacuum aspirators for cleaning; if rags are used, make sure they are not left inside the boiler.
12 |
- 06/2007 |
GB |
cod. 3540I950 |
(Rev. 00) |
FG
Routine maintenance
Soot and ash on the inside walls of the boiler and on the refractory bricks reduces the transfer of heat. However, during the operation of a boiler with wood gasification less ash is produced than during heating with conventional boilers.
Remove the ash from the combustion chamber every 1-2 days, and in any case before it is full, so as to leave sufficient space for combustion.
BIf the ash is still hot, use protective gloves.
Put the ash in a non-flammable container provided with a lid.
Carry out thorough cleaning at least once a week:
•Open the loading door and brush the combustion residuals in the ash compartment through the opening between the burner plates.
•Clean the inside walls of the combustion chamber with a brush
•Remove the loose soot and ash from the combustion chamber.
•Check perfect door closure seal. Also make sure there is no tar or condensate dripping from the smokebox.
BDo not clean the burner plates with a wire brush, as they may become damaged.
Extraordinary maintenance
Clean the fume ducts once a month:
•Remove the top cover of the casing
•Open the inspection door at the back of the boiler (see fig. 6).
•Remove the turbulators and clean the fume ducts with a tube brush.
fig. 6 - Fume duct cleaning
GB |
- 06/2007 |
13 |
cod. 3540I950 |
(Rev. 00) |
FG
Periodical check
To ensure correct operation of the unit over time, have qualified personnel carry out a yearly check, providing for the following:
•Check and if necessary clean the boiler and fume ducts as indicated in the previous paragraph.
•Remove the fume extractor and clean the fan.
•Check the conditions of the burner plates.
•Check the seal of the ash compartment and loading door; replace the gasket if necessary.
•The control and safety devices must work properly.
•The fume exhaust circuit must be perfectly efficient.
•The exhaust pipes and terminals must be free of obstructions and leaks
•The burner and exchanger must be clean and free of deposits. For possible cleaning do not use chemical products or wire brushes.
•The water pressure in the system when cold must be approx. 1 bar; otherwise bring it to that value.
•The circulating pump must not be blocked.
•The expansion tank must be filled.
3.4 Troubleshooting
Diagnostics
In case of operation anomalies or problems, the display flashes and a fault identification code appears.
Table. 1 - Fault list
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Fault |
Fault |
Possible cause |
Cure |
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code |
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E05 |
Heating temperature sensor |
Sensor damaged or short |
Check the wiring or replace the sensor |
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fault |
circuited |
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E06 |
Heating temperature sensor |
Sensor damaged or wiring dis- |
Check the wiring or replace the sensor |
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fault |
connected |
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14 |
- 06/2007 |
GB |
cod. 3540I950 |
(Rev. 00) |
FG
4.Technical data and characteristics
4.1Dimensions, connections and main components
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A |
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C |
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86 |
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10 |
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360 |
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240 |
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16 |
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E |
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F |
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B |
D |
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L |
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275
244
G H
fig. 7 - Dimensions, connections and main components
I
11
Model |
A |
B |
C |
D |
E |
F |
G |
H |
I |
L (Ø) |
Fg 30 |
550 |
970 |
750 |
550 |
457.7 |
600 |
195 |
160 |
652.5 |
130 |
Fg 40 |
550 |
1150 |
750 |
550 |
637.5 |
780 |
195 |
160 |
812 |
150 |
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Fg 50 |
600 |
1150 |
930 |
730 |
627.5 |
780 |
220 |
185 |
812 |
150 |
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Key
10System delivery
11System return
16Fan
275System water drain
GB |
- 06/2007 |
15 |
cod. 3540I950 |
(Rev. 00) |
FG
4.2 Pressure loss
mbar
20
18
16
14
12
10
8
6
4
2
0
0 |
500 |
1000 |
1500 |
2000 |
2500 |
3000 |
3500 |
4000 |
4500 |
5000 |
portata lt/h
4.3 Technical data table
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Unit |
Value |
Value |
Value |
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Model |
|
FG 30 |
FG 40 |
FG 50 |
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Max. heating capacity |
kW |
34.9 |
46.2 |
57.5 |
(Q) |
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Min. heating capacity |
kW |
16.9 |
22.3 |
27.8 |
(Q) |
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Max. heat output in heating |
kW |
30 |
40 |
50 |
(P) |
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Min. heat output in heating |
kW |
15 |
20 |
25 |
(P) |
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Efficiency Pmax |
% |
86 |
86.5 |
87 |
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Efficiency Pmin |
% |
89 |
89.5 |
90 |
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Working pressure in heating |
bar |
3 |
3 |
3 |
(PMS) |
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Empty weight |
kg |
185 |
220 |
286 |
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Combustion chamber volume |
dm3 |
100 |
140 |
200 |
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16 |
- 06/2007 |
GB |
cod. 3540I950 |
(Rev. 00) |
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