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INSTALLATION MANUAL

1. E 5 80 213 12 Imi 2 3 7a ne b 17 11 2 Il DA 16 15 5 211 1 Power Plus modular system 13 Safety valve connection 2 Hydraulic compensator 14 Thermometer connection 3 Gas supply 15 Drain valve 4 Automatic vent valve 16 Flanged pipe 5 Maximum pressure switch connection 17 Manifold delivery sensor trap 6 Control thermometer connection 18 Disconnect valves 7 Gas shut off sensor trap 19 System pumps 8 Bimetallic thermometer connection 20 Non return valves 9 6 bar pressure gauge connection 21 Outlet connection 10 Collector temperature sensor socket 22 Flue gas exhaust manifold connection 11 Expansion tank connection 23 Drain 12 Return thermometer connection 2 8 gas evacuation for installations in a central heating plant When constructing evacuation lines for installations in a central heating plant materials must be used that are resistant to products of combustion temperature between 40 and 100 relative humidity also above 100 in class W1 according to UNI EN 1443 typically stainless steel or plastic materials It is also necessary to guarantee the tightness of the entire evacuation line with regard to the permeability
2. MODEE 115 HI 150 200 Fuel G20 G30 G31 Device category 12 3 Device type B23 B53 Furnace heat output ref PCS min max 16 0 127 9 16 0 150 16 0 200 kW Furnace heat output ref PCI min max 14 4 115 14 4 134 9 14 4 179 8 kW Useful heat output 80 60 C 112 9 132 5 176 6 kW Useful heat output 50 30 C 123 8 145 3 193 6 kW Useful heat output 60 40 C 122 0 143 1 190 8 kW Useful efficiency ref PCI 80 C 60 C 98 2 926 Useful efficiency ref PCI 50 C 30 C 107 7 926 Useful efficiency ref PCI Tm 50 C 60 C 40 C 106 1 926 Useful efficiency at 30 ref PCI 80 C 60 C 98 7 Useful efficiency at 30 ref PCI 50 C 30 C 108 7 Useful efficiency at 30 ref PCI Tm 50 C 60 C 40 C 106 6 Chimney loss with burner operating 1 9 Chimney loss with burner off 0 1 Casing loss Tm 70 C 0 5 26 Flue gas temperature Return temperature 5 C CO2 at minimum 9 0 G20 10 4 G30 31 926 CO2 at maximum 9 0 G20 10 4 G30 31 926 CO at minimum maximum less than 11 91 mg kWh NOx Class 5 aximum heating operating pressure 6 bar aximum permitted temperature 90 C Boiler water temperature selection range 3 C 20 80 Water capacity 15 15 20 Electrical supply 230 50 60 V Hz Maximum electric power consumption 675 684 912 W Electric degree of protection X4D IP
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4. 2 33 34 Gy Beretta AN In the case of low temperature systems select a temperature between 20 and 45 By setting the low temperature type system the maximum deli very temperature setting will be limited to 50 Par 23 T CH Low limit A Changing the delivery temperature involves chan ging the climatic curve see the Heat control set ting This change may only be made by Technical Assistance Centre If the system is connected to a boiler set parameter 6 pre set to O no DHW service To do so access the Installer programming mode and set parameter 6 to 2 for a boiler with a sensor 6 for a boiler with a thermostat Also set parameter 9 DHW_Priority to 2 to have absolute priority If the boiler is equipped with an NTC sensor the required temperature can be set from the display between 10 C and 50 C If the boiler is equipped with a thermostat the required temperature is set directly on the boiler whereas parameter 3 must be left at 50 Press the button two times the domestic hot wa ter temperature will be displayed preceded by the symbol 3 press Set esc the relative setpoint is displayed and the two digits to the right will flash To change this value press or lt To confirm press ow o oa saz
5. 0 01215055914 INIS sl 9 EA ETLE SED EjONEA JQ 9101810019 8524 291 ana ene wer Ya 4 B19 Ip ejjeis ojod je The circulators must be connected with the interposition of suitable contactors with manual emergency actuation 14 Q 1 12 Control panels I 10 11 12 13 14 15 D O 1415 16 17 Electric power supply signal Master user interface Slave user interface Slave card operating status signal FLASHES in absence of heat demand FLASHES QUICKLY during the ignition cycle ON in presence of a flame Single heating element block signalling OFF in absence of errors FLASHES QUICKLY in case of errors that can be deactivated automatically ONin case of permanent errors Single heating element slave reset button
6. The system will turn on in mode until the demand is satisfied When the modular system is in stand by the Master unit display will be in DISPLAY mode and the three digits will be 1 followed by the delivery temperature The green LED 4 will flash On Error O aj Bo Refer to the DISPLAY mode chapter for more information about the system display types If there are any ignition or operating faults in any heating element the control panel display will start to flash and the red LED 5 will turn on Error On There are two types of errors Type A errors which can only be turned off by pres sing the RESET button Type E errors which turn off when the cause that de termined them has disappeared see the ERROR mode chapter and the Fault code chapter 3 2 Checks during and after initial start up After start up check that the Power Plus Box system is car rying out the following correctly the start up and subsequent shut off procedures clo sing the zone thermostat contacts display of the DHW temperature only with a boiler in stalled and the heating temperature by pressing the lt gt button two times If a boiler is installed check that parameter 6 is set correctly 2 boiler with sensor 6 boiler with thermo stat and that operation is correct by opening the hot water tap Check th
7. 1 13 7 Error mode The display starts to flash in case of a fault originating from any heating element Follow the procedure indicated for identifying the errors POS PROCEDURE DISPLAY 1 The display starts to flash to indicate one or more errors 80 Press x the address of the first unit will appear on the display alternating with the first error code Press again to display the rest of the errors for this unit 1 b The errors of the subsequent units that are not functioning will be displayed in succession pressing the lt button By pressing the lt button the errors will be displayed in reverse nm order E g unit 2 error code E05 If the errors originate from the Master card they are displayed as unit 00 errors OO error code 2 Press Set esc to exit Error mode and return to Display mode See the chapter Fault list for a complete list of the errors 1 13 8 Permanent block In the case of burners with a permanent block the Reset button must be pressed to reset their operation If the Reset button is pressed while in Display mode all the Slave heating elements will be reset If the Reset button is pressed while displaying the error that caused the permanent block only the heating element related to the block will be reset 2 INSTALLATION 21 Unpacking the product The Power Plus Box condensing system is supplied on a pallet strapped
8. 55 15 1 13 User interface 16 1 13 1 Display mode 17 1 19 2 Display mode esst opem eg tt 17 1 13 3 Changing the user parameters 18 1 13 4 Monitor mode 18 1 13 5 Installer programming 19 1 19 6 TeSt Mode i BR HERI pd eben 20 113 7 Eror MOUS nier Ree 20 1 19 8 Permanent DbloGK m e 20 2 INSTALLATION 21 2 1 Unpacking the 21 22 OPENING x RR 21 2 3 Overall dimensions and weights 22 24 Handling ce ebbe pt 23 2 9 Installation premises 23 2 6 Installation in older systems and systems requiring roderniSatiOni cea E meh 23 2 7 Hydraulic connections 24 2 8 Flue gas evacuation for installations in a central heating plant isses cere e en 25 2 9 Condensate evacuation 26 2 10 Condensate 26 2 11 Electrical connections 27 2 12 Outdoor sensor 30 2 13 System filling and emptying 31 2 14 Preparing for initial 5 32 The following symbols are used in this manual AN CAUTION Identifies actions that require caution and adequate preparation e STOP Identifies act
9. Frequent tripping of the system safety valve System safety valve Check calibration or efficiency System circuit pressure CH expansion vessel Check the circuit pressure Check pressure reducer functioning Check the efficiency of the expansion vessel 4 WATER IN CENTRAL HEATING SYSTEMS INTRODUCTION Water used in central heating systems MUST be suitably treated to ensure the correct functioning of those systems and to guarantee an extended working life for boilers and all other system components This applies not only to exi sting systems but to newly installed systems too Sludge lime scale and pollutants present in the water can cause permanent damage to the heating unit also within a short time and regaraless of the quality standards of the materials used Contact the Technical Assistance Centre for any further in formation on type and use of additives AN Always conform to the standards and legislation ap plicable in the country of installation WATER IN CENTRAL HEATING SYSTEMS INSTRUCTIONS FOR THE DESIGN INSTALLATION AND MANAGEMENT OF CENTRAL HEATING SYSTEMS 1 Chemical and physical characteristics of water The chemical and physical characteristics of water used in central heating systems must conform to the requirements of EN 14868 standard and to the following tables STEEL BOILERS with furnace power 150 kW gala Regular ser
10. i gt 3 Scarico Civile 2 10 Condensate neutraliser The N2 and HN2 neutralisation kits are available for con densate neutralisation N2 TYPE NEUTRALISATION KIT The N2 TYPE neutralisation units were designed for systems equipped with the central heating plant condensate outlet trap located lower than the boiler condensate outlet This neutralisation kits does not require electric connections Description Sizes L Width 400 mm H Height 220 mm P Depth 300 mm HN2 TYPE NEUTRALISATION KIT The HN2 TYPE neutralisation units were designed for sy stems equipped with the central heating plant condensate outlet trap located higher than the boiler condensate outlet This neutralisation kits does require electric connections Description Sizes L Width 400 mm H Height 220 mm P Depth 300 mm Quantity of granulate 25 kg Maintenance Neutralisation device maintenance must be performed at regular intervals and as required minimum once per year The requirement for maintenance depends on the system characteristics For this purpose the filling level of the dolo mitic granules must be checked The minimum filling level is equal to 15 cm starting from the upper edge of the box The first filling of neutralisation product is sufficient at least for one heating season in the case of maximum formulation of condensate The ope
11. the gas supply line and tank if installed are imple mented according to the specific standards the expansion tanks ensure total absorption of the flu id expansion in the system the system has been cleaned of sludge and deposits 2 7 Hydraulic connections The Power Plus Box condensing systems are designed and built to be installed in hot water heating systems They are used only for this purpose and any other erroneous or unreasonable application is prohibited Before starting with installation establish the outlet direction of the water gas and condensate manifolds and of the flue gas manifold in the case of an installation in a central heating plant Also take the electrical connections 230V 50Hz power supply of the condensing modules into account Position the modular system s and the technical cabinet with the hydraulic separator near the system s delivery and return manifolds To make it easier to position the modular system in the area of installation refer to the Handling paragraph Adjust the feet of the cabinet if necessary to level them making it possible to easily open and close the doors and align the manifold flanges Counterflanges and blind flanges for the water and gas manifolds can be purchased easily on the market A Provide the system filling draining and safety components expansion tank etc A The use of a hydraulic compensator is mandatory COMPENSATORE POWER PLUS BOX IDRAULICO
12. 800 30 200 Equivalent length for the various line elements m Type of element with 160 mm with 200 mm 45 bend UNA 1 7 87 bend 155 7 5 T union 7 5 7 5 AN The flue must be sized according to the current standard UNI 7129 and be as straight as possible without ob structions or constrictions A A steam trap is mandatory for flue gas lines longer than 3 metres A Make sure that there is a minimum slope of 3 in the horizontal sections of the flue gas manifold to avoid the accu mulation of condensation A In the event of installation with air intake from the premises both in the heating unit and externally avoid obstructing the passage of air under the metal cupboard 25 26 Cy Beretta 2 9 Condensate evacuation Power Plus Box condensation systems produce a conden sate flow depending on the operating conditions The ma ximum hourly flow of condensation produced is indicated for every model in the technical data table The condensate outlet system must be sized for that value and the cross section may not be smaller in any section than the dimen sion of the connection to the condensate outlet manifold SC The condensate outlet manifold is supplied already instal led Therefore it is only necessary to connect the outlet SC coming from the modular system to the drainage system uin A Always keep the inclination angle i greater than 3 and the diameter of the condensate outlet pipe al
13. t 2 5 re E o 27 sunu E 2 Bo g E oj jojjo e e 2 o lo o e 5 S9 gt g 99 al Ims E SE e 5 5 s E etr LEA o o of af af E e do 000 e e e e e 2 3 3 3 3 a lt 828 ASE 5 5 5 5 5 5 E ofa 25 uu gt XN NEA UO e B T XIN NEA FO 298 SAN NPA ION DICE edu 9524 sl s e edud g S B Ss 5 Zorg j 5 0 04 9564 34 HS PUO gt 8 o 2 Si ques Edul g 9563 8 icto ques Eduiog oJinaN 23 m o 2 23000 2 MODULAR SYSTEM IG CS PB PZ1 PZ2 VM CR SB SZ1 SZ2 SE TA1 TA2 Modular system main switch Contact for external safeties Boiler circulator Zone 1 circulator high temperature Zone 2 circulator low temperature Mixer valve Remote control accessory available separately Analogue input Boiler sensor Zone 1 sensor Zone 2 sensor Outdoor sensor Zone 1 room thermostat high temperature Zone 2 room thermostat low temperature HEATING ELEMENT C SM SR SF TS PD Heating element circulator or 2 way valve Flow probe Return probe Exhaust flue probe Safety thermostat Gas valve Water differential pressure switch Ignition detection electrode IG1 1G
14. Initial filling water ph 6 8 7 5 9 5 Hardness fH lt 10 lt 10 Electrical conductivity us cm bi Chlorides mg l lt 20 Sulphides mg l lt 20 Nitrides mg l lt 20 Iron mg l lt 0 5 STEEL BOILERS with furnace power gt 150 kW Regular ser Initial filling water ph 6 8 7 5 9 5 Hardness fH lt 5 5 Electrical conductivity us cm 5 208 Chlorides mg l lt 10 Sulphides mg l lt 10 Nitrides mg l lt 10 Iron mg l 0 5 7 values for water in system after 8 weeks of functioning General note on water used to top up systems if softened water is used to top up a system 8 weeks of functioning after topping up verify that the water in the system respects the above limits in particular for electrical conductivity this check is not necessary if demineralised water is used to top up the system 2 Central heating systems AN Do not use automatic filling devices to add water to central heating systems Use a manual device inste ad and record top ups in the system service book AN If there are more than one boiler they must all be put into service either contemporarily or with a very low rotation time during the initial period of service So as to evenly distribute the limited quantity of initial lime scale AN A flushing cycle must be programmed after the plant has been installed to flush out any installation debris AN Water used to fill
15. Instrument panel FOURTH heating element switch only for Power Plus Box 200 THIRD heating element switch SECOND heating element switch FIRST heating element switch Main control panel Modular system main switch only accessible by tur ing the main control panel Electric power supply signal Modular system block signal E Set 22 21 20 19 18 16 17 18 19 20 21 22 Display Value increase button Value decrease button Save button Parameter selection button Operating mode selection button Master reset button 15 16 Gy Beretta Functional notes The Power Plus Box modular system control panel mana ges Ihe DHW priority function which in the case of a DHW demand the master card can also serve the high or low temperature circuit The anti freeze function also active in stand by mode which starts the high temperature circuit circu lator and the loop circulator if the manifold temperatu re drops below 5 C If there is an outdoor sensor the circulators turn on if the outdoor temperature drops below 3 C If after 10 minutes the manifold tempera ture is less than 5 C a burner turns on at maximum power until the manifold temperature reaches 20 If after 10 minutes the manifold temperature exceeds 5 C but the outdoor temperature is lower than 3 C the circulators remain active until the outdoor temperatu re goes above that value cascade management function t
16. 300 i 1 Pressure lost by 200 1 the fluid when 1 crossing the 100 1 heating element 0 500 1000 1500 2000 2500 3000 3500 4000 Flow rate l h Heating element pressure drop at 2000 l h 550 mbar Flow rate necessary for every heating element 2000 I h AN At the first start up and at least once a year the ro tation of the circulator shaft should be checked as especially after long periods of not being operated deposits and or residuals could impede its free ro tation AN Before loosening or removing the circulator cap pro tect the electric devices located underneath from any water that exits e It is prohibited to operate the circulators without wa ter 12 Cy Beretta 1 10 Location of sensors THERMOSTAT triggering at 90 SAFETY POWER PLUS BOX HEATING SENSOR FLUE GAS SENSOR HYDRAULIC COMPENSATOR DELIVERY SENSOR HEATING RETURN triggering at 80 43174 521 522 SB SE PZ1 PZ2 PB VM 80 C Delivery manifold sensor Low system temperature sensor Boiler sensor Outdoor sensor Zone 1 circulator high temperature Zone 2 circulator low temperature Boiler circulator Mixer valve 50 C 22 60 C AN Install sensors SZ2
17. 5 seconds to access Monitor mode This mode is used to check the operating values for every sy stem unit addresses from 1 to 60 POS OPERATIONS DISPLAY 1 From current T1 position at 80 C 8 co i 2 Press Set esc for 5 secs The displays shows it is possible to read the values functio nal status of unit 1 3 Press or lt to scroll and read the values of the desired unit e g fig unit 19 Pressing lt gt the first value of the selected unit will appear Afterwards by pressing the 4 same button the next values will be visualized e g fig 1st value flow temperature NTC 70 C eu 5 Press Set esc to exit monitor mode The display will return to display mode function if it is not pressed within 5 minutes or if no operation has been done co 25 DI 25 a Lo The following values for each single unit can be visualized with POS DIMENSIONS DISPLAY 1 Flow temperature e g 70 C 2 Return temperature e g 50 C e 5 5 Bi 3 Exhaust flue temperature e g 60 C 4 lonization current index from 0 to 99 E g fig lonization current index 44 Fan PWM signal 96 5 If PWM 100 it corresponds to 99 on the display E g fig with 66 Flowmeter contact open and closed e g fig contact open then P contact closed F 0 0 F 7 Circulator or motor driven va
18. CONTROL PAR 14 1 If the high temperature circuit attenuation is equal to 0 At tenuation highzPar 21 0 its behaviour is the same as the previous paragraph with the exception that the setpoint is calculated based on the outdoor temperature If the outdoor temperature Tout minzPar 37 preset to 0 C then setpoint 2setpoint T Ch high If the outdoor temperature Tout max Par 38 preset to 18 C then setpoint T ch high foot Par 18 preset to 50 C The setpoint is calculated linearly between the 2 outdoor temperature values Preset to 0 2 Attenuation Low LOW TEMPERATURE circuit attenuation function parameter 25 This paragraph is similar to the previous paragraph for the low temperature circuit There are 2 cases Fixed point operation Par 2220 Operation with climatic control Par 22 1 FIXED POINT OPERATION PAR 22 0 With low temperature circuit attenuation disabled Par 25 0 at the closure of the low temperature circuit thermo stat heating demand is activated When opened the sy stem turns off The Master control unit activates the low temperature cir cuit pump if the parameter for the third pump is set to 1 P34 1 On the Master control unit it is possible to set the low tem perature circuit setpoint Setpoint_T_CH_Low Par 3 pre set to 40 C and can be set between 10 C and T_CH_low_li mit Par 23 which in turn is preset to 50 C The setpoint used will be the one set with parameter
19. Description USER parameters If Par14 0 it is the high temperature 6 circuit setpoint 1 SetPoint_ch_high Li Par d7 C Part4 t itis the maximum high tem perature circuit temperature 2 SetPoint_DHW 10 Par 8 50 C If Par22 0 it is the low temperature o circuit setpoint 3 SetPoint ch low 10 23 40 If Par22 1 it is the maximum low tempe rature circuit temperature INSTALLER parameters accessible with a password 22 0 No DHW service 1 Instantaneous with NTC sensor 6 DHW type 0 6 0 2 Boiler with NTC sensor 5 Instantaneous with flow switch 6 Boiler with thermostat 7 P DHW max 1 255 230 Maximum power speed in DHW mode 8 T DHW limit 10 80 60 Limit for DHW user set 0 Shifting A 9 DHW _ priority 0 2 0 1 Shifting B 2 Absolute priority o Modular system temp in DHW mode 10 T tank extra 0 50 30 C Par 2 Par 10 T tank hyst up 0 20 1 C Upper DHW differential 12 T_tank_hyst_down 0 20 5 C Lower DHW differential 13 N _bruc_DHW 1 60 60 Max no of burners in DHW mode 0 Fixed temperature 1 Weather with probe outside 14 CH type high 0 3 1 2 0 10 Vdc power 3 0 10 Vdc temperature 15 P_ch_max 1 255 230 Maximum power speed in CH mode 0 No circuit priority 16 CH priority 0 2 0 1 Priority to high temperature circuit 2 Priority to low temperature circuit 17 T CH high limit 10 80 80 Limit for high temperature circuit user taedia set Min high circuit setpoint at maximum 18 T CH h
20. Dispose of packa ging material in compliance with applicable legisla tion 21 22 Cy Beretta 2 3 Overall dimensions and weights 660 GAS E 9 5 T d 1250 __ 95 295 650 Power Plus Box DESCRIPTION 115 HI 150 200 MI System delivery manifold 5 DN 125 PN 6 DN RI System return manifold 5 DN 125 PN 6 DN GAS Gas manifold 3 DN 80 PN6 DN SF Flue Manifold 160 mm SC Condensate drain manifold 50 mm Water drainage system weight 310 310 340 Kg 2 4 Handling A transpallet or forklift must be used for handling A transpallet or forklift must be used for handling place two wooden boards 1 near the pallet 2 slide the modular system above the wooden boards adjust the feet 3 of the modular system until they rest on the ground slide the wooden boards out A The packaging material must be disposed of care fully and must not be abandoned as it is a source of potential danger 2 5 Installation premises The Power Plus Box systems models EXT are designed for outdoor installation In the case of installation indoors mo dels INT they are B23 category devices and must be in stalled in p
21. PZ1 and the system pump PZ2 if parameter P3420 On the Master control unit it is possible to set the high tem perature circuit setpoint Setpoint T CH High Par 1 pre set to 70 C and settable from 10 C to T CH high limitzPar 17 which is in turn preset to 80 The setpoint used will be the one set with parameter 1 The burner is on when Manifold temperature lt Setpoint ignition hysteresis Ignition hysteresis can be set CH High hyst on Par 19 preset to 7 C can be set between 0 and 20 C The Master control unit converts the heat demand into power demand for each slave control unit The burners are off when Manifold temperature gt Setpoint shut off hysteresis Shut off hysteresis can be set CH High Hyst off Par 20 preset to 3 can be set between and 20 With the high temperature circuit attenuation parameter Par 2120 the high temperature thermostat contact is igno red and a heat demand is present for the high temperature circuit when Manifold temperature lt Setpoint ignition hysteresis The heat demand stops when Manifold temperature gt Setpoint shut off hysteresis The setpoint in this case coincides with the value set for parameter 1 Setpoint t ch high if the high temperature thermostat contact is closed whereas it is calculated as the value set for parameter 1 less the attenuation Setpoin t t ch high Attenuation high if the contact is open OPERATION WITH CLIMATIC
22. a system for the first time and water used to top it up must always be filtered using syn thetic or metal mesh filters with a filtration rating of no less than 50 microns to prevent sludge from forming and triggering deposit corrosion A The heating system must be flushed out and cleaned with good workmanship before filling up the existing systems The boiler may not be filled until after the heating system has been flushed out 2 1 New central heating systems The system must be filled up slowly the first time once it is filled and the air expelled it should never need to be topped up again Systems should also be operated at maximum working temperature the first time they are started up in order to facilitate de aeration Gas is not released from the water at low temperatures 2 2 Reconditioning old central heating systems If a boiler has to be replaced do not refill the entire cen tral heating circuit if the quality of water in it conforms to requirements If the quality of water fails to conform to re quirements either recondition the old water or separate the water circuits water in the boiler circuit must conform to requirements 3 Corrosion 3 1 Deposit corrosion Under deposit corrosion is an electrochemical process due to the presence of sand rust etc inside the mass of water These solid substances generally deposit on the bottom of the boiler sludge on tube and pipe heads or in the gaps between pipes a
23. and protected by cardboard packaging Its condition and compliance with what was ordered must be checked immediately The specific characteristics of the product are indicated on the outside model power product code and serial number If there is a discrepancy between what was ordered and what was received imme diately contact the local agent warehouse or sales service 2 2 Opening Remove the straps 1 and the cardboard packaging 2 Strap Cardboard packaging Pallet Modular condensing system Document envelope containing Instruction manual Hydraulic test and warranty certificate Barcode labels 6 Accessory envelope containing Natural gas to LPG transformation kit Door key The following is also supplied positioned on the base inside the modular system 2 5 DN 125 PN 6 flanges complete with gaskets 1 3 DN 80 PN 6 flange complete with gaskets polypropylene coupling pipes for the flue gas mani fold and condensate outlet positioned inside the control panel low temperature boiler delivery sensor outdoor sensor AN The document envelope 5 must be kept in a safe place Any copies must be requested from Beretta who will send the new documentation within 45 days and who reserves the right to charge for the copies e Do not dispose of packaging material into the envi ronment or leave it within the reach of children since it can become a potential hazard
24. chapter If there are more than two modular systems the addres ses must be configured from the second modular system onwards To do so see the paragraph Setting addresses for cascade coupling If there is a low temperature system set parameter 34 1 Adjust the room thermostats for the high and low tem perature zones to the required temperature 20 C or if the systems are equipped with timer thermostats or a time programming unit make sure it is on and adjusted 20 C 200 LES O press the button the manifold delivery temperatu re will be displayed preceded by the symbol 1 press Set esc the relative setpoint is displayed and the two digits to the right will flash To change this value press or lt To confirm press On Error e al Die ei GO 2 press the button four times the maximum tempe rature of the low temperature circuit will be displayed preceded by the symbol 6 On Error b 50 w m 4 3 GO 6 press Set esc the relative setpoint is displayed and the two digits to the right will flash To change this value press or V To confirm press On Error p b 2388 do
25. ee a T AT SI Guns pr 1 2 JL 1 Gaslabel It is applied on the front part of the device and indicates the type of gas used by the modular system and the coun try of destination 2 Technical data plate It indicates the technical and performance data 3 Serial number plate This is located on the boiler body and specifies the serial number model and furnace power A Spare parts and or technical operation require the exact identification of the corresponding model The absence of tam pering with or removing the identification plates or other does not make it possible to reliably identify the product makes any installation and maintenance operation difficult and invalidates the warranty 1 6 System layout Control panel Single heating element Control panel Bus cable passage cable gland for the cascade connection Flue gas manifold Gas manifold System delivery manifold Condensate drain manifold System return manifold Single heating element flue gas analysis outlet Fan Single heating element flue gas exhaust union Automatic vent valve Safety thermostat Drain valve Manual diverting valve Circulator or 2 way valve Gas valve Comburent air intake union Gas cock Flow probe Ignition detection electrode Exchanger Return probe Exhaust flue probe Di
26. that exits Connect a plastic pipe to the drain tap 6 located on the system return line connect a plastic pipe to the diverting valves 1 for each heating element open the return tap 2 open the drain tap 6 and the diverting valves 1 the combustion product evacuation lines have been suitably implemented 32 2 14 Preparing for initial startup Before igniting the Power Plus Box modular system and performing a functional check it is important to first check that the heating system shut off and gas taps are open the type of gas and the supply pressure comply with the features of the modular system 2 Beretta 3 COMMISSIONING AND MAINTENANCE 3 1 Initial startup Turn the main system switch on ce J loosen the screw 1 turn the main control panel 2 and access the main switch of the modular system 3 turning it to on The green indicator lights 4 and 5 will turn on turn the switches 6 for each heating element to on the green SLAVE electric power supply indicator light 7 for every heating element will flash The system will perform a self diagnostics cycle after which it will Switch to DISPLAY mode the display 8 shows the system status and the tem perature measured by the high temperature circuit sensor see the Display mode
27. thermostat In the case of a boiler with a thermostat if the input is a clo sed contact the DHW demand is activated if it is an open contact the demand stops Preset to 0 3 DHW Priorit DHW priority parameter 9 0 Shifting priority A The purpose of shifting priority function A is that the system can also serve heating if the heating demand is low The system responds to the heating demand if Setpoint Ch 50 C lt Temp oollettore lt Setpoint Ch 190 Setpoint Ch Setpoint of the high or low temperature cir cuit depending on demand 1 Shifting priority B The purpose of shifting priority function B is that the system never stops the heating service for too much time The system responds to the heating demand if Setpoint_Dhw T_Tank_extra 50 Temp collettore lt Setpoint_Dhw T_tank_extra 1 C T_tank_extra Par 10 preset to 30 C 2 Absolute priority only DHW service Preset to 0 3 6 Heat control setting 1 Attenuation High HIGH TEMPERATURE circuit attenuation function parameter 21 There are 2 cases Fixed point operation Par 1420 Operation with climatic control Par 1421 FIXED POINT OPERATION PAR 14 0 With the high temperature circuit attenuation disabled 21 0 when the high temperature circuit thermostat is closed the heating demand is activated When opened the system turns off The Master control unit activates the high temperature cir cuit pump
28. turned off too later after Check the proper operation of the gas valve the gas valve closed Replace the gas valve E type error on the slave card for apu A22 22 yp more than 24 Check the history of type errors It is an error inside the clock A23 23 ihternalcisckerror COM if the current is not present for a few mo The error disappears after a few seconds The measured fan speed varies too much with the read Speed A24 24 Fan error Check the fan Check the fan s electrical connection Replace the fan A25 21 Internal error Replace the Slave card Slave error list automatic reset nection N DE the Cause Troubleshooting E33 33 Line and neutral inverted Restore the correct line neutral electrical connection Reset button error Wait for the error to disappear E34 34 It was pressed more than 7 times If the error did not disappear after max 40 min replace 30 min the Slave card Water differential pressure switch Check the correct flow rate in the water circuit of the indi E35 35 error vidual unit 2 m3 h per unit contact open Replace the water pressure switch tar 500 It h E36 36 Internal error Replace the Slave card Clean the electrodes E37 of Flame detection error Replace the electrode pan Check the flue gas sensor connector E38 38 Flue gas sensor short circuiting Replace the flue gas sensor Check the flue gas sensor co
29. your purchase Beretta CONFORMITY The Power Plus Box modular condensing systems comply with Directive 2009 142 EC Gas Appliances Directive 92 42 EEC on efficiency requirements and Annex E and Pres Republic Decree n 412 26 Au gust 1993 Electromagnetic Compatibility Directive 2004 108 EC Low Voltage Directive 2006 95 EC Boiler and Condensation UNI EN 677 standard C 0085 Furthermore modular condensing systems Power Plus Box fulfil the provisions of chapter R 3 B collection R ISPESL See annex AN This product must only be used for the purpose for which it is designed and made as specified by Beretta Beretta declines all responsibility contractual or other for damage to property or injury to persons or animals caused by improper installation adjustment maintenance or use 5 1 GENERAL INFORMATION 4 31 1 General information 4 1 2 PRECAUTIONS i e siria i it 4 1 3 Description of the appliance 4 1 4 5 1 5 6 1 6 7 1 7 Coupling 8 1 8 Technical data coo e d m 9 wI Water el Gulb nores dau b Rhe Ge beets epe 10 1 10 Location 12 1 11 Wiring diagrams sero RR 13 1 12
30. 168 1 11 Wiring diagrams
31. 2 and outdoor sensor connected the outdoor temperature lt 3 C par 35 the pump continues to operate until the outdoor temperature gt 3 C Parameter 35 can be set between 30 C and 15 Preset to 3 5 Power control mode Cascading management parameter 33 To manage the power delivered by the system two ca scading strategies are possible In both cases the Master control unit can only add a new burner when another is on If the Master control unit must increase the number of igni ted burners first check that the next burner can be ignited no errors present and modular system temperature below the maximum Otherwise check another burner If no bur ner is ready for ignition the master will decrease the num ber of burners to ignite 39 40 Gy Beretta MODE MINIMUM QUANTITY OF BURNERS IGNITED PAR 33 0 System power modulation is controlled by a PID regulator which controls the manifold temperature and the setpoint is that of the active circuit high or low temperature circuit setpoint or DHW setpoint The PID has a direct influence on the last 2 burners ignited whereas the previous ones operate at maximum power If the manifold temperature Setpoint 5 C the next bur ner is ignited and both are managed by the PID regulator The Master control unit waits for 305 and then if the manifold temperature Setpoint 5 C another burner is ignited The first burner operates at maximum power whereas t
32. 3 The burner is on when Manifold temperature lt Setpoint ignition hysteresis Ignition hysteresis can be set CH_Low_hyst_on Par 26 preset to 5 C can be set between 0 and 20 C The Master control unit converts the heat demand into power demand for each slave control unit The burners are off when Manifold temperature gt Setpoint shut off hysteresis Shut off hysteresis can be set CH_Low_Hyst_off Par 27 preset to 3 can be set between and 20 C With the low temperature circuit attenuation parameter Par 25 0 the low temperature thermostat contact is ignored and a heat demand is present for the low temperature cir cuit when Manifold temperature lt Setpoint ignition hysteresis The heat demand stops when Manifold temperature gt Setpoint shut off hysteresis The setpoint in this case coincides with the value set for parameter 3 Setpoint_t_ch_low if the low temperature thermostat contact is closed whereas it is calculated as the value set for parameter 3 less the attenuation Setpoin t_t_ch_low Attenuation_low if the contact is open OPERATION WITH CLIMATIC CONTROL PAR 22 1 If the low temperature circuit attenuation is equal to O At tenuation lowzPar 25 0 its behaviour is the same as the previous paragraph with the exception that the setpoint is calculated based on the outdoor temperature If the outdoor temperature Tout_min Par 37 preset to 0 C then setpoint 2setpoint T C
33. 3 low temperature circuit delivery temperature T6 To change the relative setpoints press the Set esc button the relative value will appear the two digits on the right will flash ifthe value should not be changed press Set esc again to return to display mode if the value should be changed press and lt until the required value appears on the display Press OK to save the new value The displayed value stops flashing and the display returns to the display mode For example s sake here below is a table showing the procedure for changing the setpoint value of the low temp heating system from 50 to 40 POS PROCEDURE DISPLAY 1 E g value read on display for high system 80 C 2 Press button lt to enter display mode press again and go to the first of 6 digits to visuali ze the set value e g 50 C 3 Press button Set esc 4 Press W to take the setpoint to the desired value e g 40 C 5188 5 Press OK to memorize the new value 6 After 3 secs the display will return to the display mode with the new setpoint If there is no change after pressing Set esc for 10 secs the desired value corresponding to the set one the display returns to display mode function If there is no operation after pressing buttons amp and lt after one minute the display will return to display mode The new selected value is not memorized 1 13 4 Monitor mode Press Set esc for
34. 4 FIRST FOURTH heating element switch J10 J17 Addressing microswitches Uejs s jueoe pe ue JO pied eres Jeujoue 9 qissod 104 10 9 UU09 eui sng 35 DIN DIN WS 3AV IS Byepuew DIN qun OLN 1 eiueujos J8 men sues 0 suog zejueulv q 5065 indur aiueyjos 0 Hid 0121505590 Sl yu 9 SED EON 9101810019 8524 29 enel ESL vr aliqsna DIN c sna AAV1S pH B19 Ip ejjeis ojod je Byepuew DIN eiueyjos suas suas zejueuiv suas indui GJ eiueyios
35. 5 15 de 12 n 10 Analogue 5 2 Input m A 2 elelleleLeluelelele 230V 50Hz The following is mandatory the use of an omnipolar magnetothermic switch line disconnecting switch in compliance with CEI EN standards contact opening of at least 3 mm respect the connection L line N neutral Keep the earth conductor 2 cm longer than the power supply conductors use cables with a section greater than or equal to 1 5 mm complete with cable terminal caps refer to the wiring diagrams in this manual for all electric operations connect the equipment to an effective earthing sy stem The circulators must be connected with the interpo sition of suitable contactors with manual emergency actuation e It is prohibited to use gas and or water pipes for the equipment s earth connection e It is prohibited to pass the power supply and room thermostat cables near hot surfaces delivery pi pes If contact is possible with parts that have tem peratures above 50 C use a suitable type of cable The manufacturer is not responsible for any dama ge caused by failure to earth connect the device and failure to comply with what is indicated in the wiring diagrams NOTE for sensor positioning see the Sensor positioning chapter 29 30 Cy Beretta 2 12 Outdoor sensor installation The correct positioning of the outdoor sensor is of funda mental import
36. 8 8945 47 4595 66 2512 85 1451 104 879 9 40568 10 17959 29 8622 48 4444 67 2437 86 1411 105 857 8 38780 11 17245 8313 49 4300 68 2365 87 1373 106 836 7 37079 12 165631 31 8016 50 4161 69 2296 88 1336 107 815 6 35463 13 15912 32 7731 51 4026 70 2229 89 1300 108 796 5 33925 14 15289 33 7458 52 3897 71 2164 90 1266 109 776 4 32461 15 14694 34 7196 53 3773 72 2101 91 1232 110 757 3 31069 16 14126 35 6944 54 3653 73 2040 92 1199 2 29743 17 13582 36 6702 55 3538 74 1982 1168 2 13 System filling and emptying The Power Plus Box filling system is not equipped with filling tap which must be installed on the system return FILLING Check that the diverting valve 1 and the system re turn tap 2 for every heating element are open open the automatic bleed valve caps 3 on each he ating element by two or three turns O open the filling tap 4 provided on the system until the pressure indicated on the pressure gauge is 1 5 bar close the filling tap 4 AN Deareation of the Power Plus Box modular system ta kes place automatically through t
37. A43 Limit thermostat defective Gas valve coil interrupted Replace the gas valve False gas valve connector contact Check the gas valve connector A05 5 Defective gas valve connector Replace the gas valve connector Poor circulation in the primary circuit Limit thermostat defective No on the N PC Cause Troubleshooting A06 6 Absent or insufficient earth con Check the earth connection nection Version SCHEDA43 Replace the Slave card 07 7 Internal error Replace the Slave card A08 8 Internal error Replace the Slave card A09 9 50HZ error The main frequency is not 50Hz A10 10 Internal error Replace the Slave card A11 11 Internal software error Press the rest button A12 12 Internal error Replace the Slave card A17 17 Delivery sensor error due to Check the correct flow rate in the water circuit of the indi exceeding the limit temp vidual unit 2 per unit A18 18 Return sensor error due to Check the correct flow rate in the water circuit of the indi exceeding the limit temp vidual unit 2 m h per unit A16 16 The limit thermostat contact is open Connector disconnected or defective with the burner off Limit thermostat defective The flue gas sensor tripped due to Heat exchange insufficient on the flue gas side inside the A19 19 overtemperature 80 C in this exchanger case the fan turns at max speed Clean the flue gas side exchanger A20 20 The flame
38. Frost protection 30 15 3 C System 01 Natural gas with flue gas exhaust lt 15m 36 Gas type 1 31 01 M gas with flue gas exhaust 03 LPG with flue gas exhaust 15m 04 LPG with flue gas exhaust gt 15m 37 T out min 20 30 0 C 37 T_out_min 20 30 0 C 38 T out max 0 30 18 ie 39 T out correct 30 30 0 C 40 T_emergency 10 80 70 C 41 Parameter reset 0 1 0 0 The slave does not verify the pressu 42 Flow switch on slave 0 1 1 re switch 43 Protocol 0 1 1 0 Eco protocol 1 Argus link new 47 48 Gy Beretta 3 10 Transformation from one gas type to another The Power Plus Box system is supplied for operating with G20 natural gas It can however be transformed to opera te with G30 G31 LPG using the provided kit AN The transformations may only be carried out by Tech nical Assistance Centre or by personnel authorised by Beretta also on already installed modular systems AN Once the transformation is complete adjust the mo dular system again by following the instructions in the Adjustments paragraph Before making the transformation disconnect the electric power supply from the device by turning the main switch to off close the gas shut off valve ON To install the kit open the two front doors in the casing parameter 36 to 03 or 04 depending on the len gth L of the flue gas exhaust line 03 L 15 m 04 L gt 15m The fan sp
39. Quantity of condensate at maximum power 16 6 21 6 28 8 kg h CONNECTIONS Delivery manifold 5 DN 125 PN 6 DN Return manifold 5 DN 125 PN6 DN Gas manifold 3 DN 80 6 DN Flue gas outlet 160 mm Condensate outlet 50 mm DIMENSIONS Height 1500 mm Width 1250 mm Depth 650 mm 10 Cy Beretta 1 9 Water circuit COON Da PWN 11 12 13 SF 4 GAS gt MI lt sc lt RI Fan 14 Relief valve Automatic vent valve AA Air inlet Burner SF Smoke outlet Heat exchanger SC Condensate outlet Drain valve MI System delivery Differential water and minimum pressure switch Circulator or 2 way valve Gas valve Flue gas exhaust union with check valve and flue gas analysis outlet Manual diverting valve Return shut off valve Gas cock Delivery sensor traps RI System return GAS Gas supply WATER SIDE PRESSURE DROP FOR EVERY HEATING ELEMENT Every heating element of the Power Plus Box modular system is equipped with a circulator whose performance curve is provided below in reference to speed 3 1200 1100 1 heating element 1000 900 4 Circulator characteristic curve 2 800 E 2 700 5 600 I _ P available for Oo i en mmm mmm ww wm Rm System circulation 5 500 I a I 400 I x I A
40. THERMAL MODULES POWER PLUS BOX INT EXT CONDENSING INSTALLATION MANUAL peretta Cy Beretta RANGE MODEL CODE POWER PLUS BOX 150 M P EXT 20020973 POWER PLUS BOX 200 M P EXT 20020974 POWER PLUS BOX 150 M V EXT 20074443 POWER PLUS BOX 200 M V EXT 20074445 POWER PLUS BOX 150 M P INT 20074450 POWER PLUS BOX 200 M P INT 20074455 POWER PLUS BOX 150 M V INT 20074457 POWER PLUS BOX 200 M V INT 20074459 POWER PLUS BOX 250 M P EXT 20074447 POWER PLUS BOX 300 M P EXT 20074448 POWER PLUS BOX 115 HI 20020972 ACCESSORIES For a complete list of accessories and details of their com patibility refer to the Catalogue Dear Customer Thank you for preferring a Beretta heating unit a modern high quality product that is able to guarantee your maxi mum well being for a long period of time with high levels of reliability and safety In particular if working together with Technical Assistance Centre Beretta that is specifically pre pared and trained to perform periodic maintenance your unit will remain at maximum efficiency levels at minimum operating costs and if required replacements with original spare parts can be made This instruction manual contains important information and suggestions that must be followed to ensure simple instal lation and the best possible use of the cod linea heating unit Please accept our renewed thanks for
41. abled by the password 7 Press Set esc to start to modify the parameters Now P XX and the respective value will be shown alternatively on the display Press amp and X to change the parameter value 8 Each time a button is pressed the alternating display of the parameter and the respective value stops for 5 seconds and only the value is displayed 9 Press to save the new parameter value To exit the installer programming mode press the Set esc button See the chapter Parameter list for a complete list of the parameters 20 Cy Beretta 1 13 6 Test mode In test mode it is possible to generate a high temperature heating demand at maximum power and at minimum power All system fans must be activated If the installer turns off the switch for some Slaves the others connected to the Master must continue to operate Proceed as follows to enter Test mode from Display mode POS VISUALIZED VALUES DISPLAY Press Set esc at same time for 5 s After 5 s select the maximum speed or the minimum speed with the lt and lt buttons 1 All system fans will operate at the selected speed The first digit indicates the selected speed maximum speed L minimum speed The other two digits display the delivery temperature E g T1 80 CO co CO B 2 Press to exit Test mode and return to Display mode
42. ance for proper climate control operation The sensor must be installed outside the building to be he ated at approx 2 3 the height of the NORTH or NORTH WEST facade and far from flues doors windows and sun ny areas Fastening the outdoor sensor to the wall gt P Unscrew the sensor protection box cover turning it anticlockwise to access the terminal board and fa stening holes trace the fastening points using the box as a template remove the box and drill the holes for the 5x25 expan sion plugs fasten the box to the wall using the two supplied dowels unscrew the cable gland nut insert a bipolar cable with a section between 0 5 to 1mm not included in the supply to connect the sensor to terminals 7 and 8 see diagram in the Electric connections chapter connect the two cable wires to the terminal board wi thout identifying the polarities fully tighten the cable gland nut and close the pro tection box cover The sensor must be positioned on a smooth wall section If there are exposed bricks or irregular walls an area with a smooth contact must be prepared The maximum length of the connection between the outdoor sensor and the control panel is 50 m In the case of connections with a cable length that exceeds 50 m check compliance of the value read on the card with a real measurement and adjust parameter 39 to make any necessary correction Correspondence table for all sensors Measured temperature
43. and SB in a trap outside the modular system Correspondence table for all sensors Measured temperatures Resistive va ues of the sensors Q T C 0 RCO TPC RCO RCO TPC TPC R CO CO 20 67739 1 28481 18 13062 37 6470 56 3426 75 1925 94 1137 19 64571 27279 19 12565 38 6247 57 3319 76 1870 95 1108 18 61568 1 26135 20 12090 39 6033 58 3216 77 1817 96 1079 17 58719 2 25044 21 11634 40 5828 59 3116 78 1766 97 1051 16 56016 3 24004 22 11199 41 5630 60 3021 79 1717 98 1024 15 53452 4 23014 23 10781 42 5440 61 2928 1669 99 998 14 51018 5 22069 24 10382 43 5258 62 2839 81 1622 100 973 13 48707 6 63 2753 82 1577 101 948 12 46513 7 64 2669 83 1534 102 925 11 44429 8 65 2589 84 1491 103 901 10 42449 9 66 2512 85 1451 104 879 9 40568 10 67 2437 86 1411 105 857 8 38780 11 68 2365 87 1373 106 836 7 37079 12 69 2296 88 1336 107 815 6 35463 13 70 2229 1300 108 796 5 33925 14 71 2164 90 1266 109 776 4 32461 15 72 2101 91 1232 110 757 3 31069 16 73 2040 92 1199 2 29743 17 13582 36 6702 55 3538 74 1982 1
44. and stops below 1 8V n e c Power kW 0 1 2 3 4 5 6 7 8 9 10 Voltage Volt The burner ignited when Delivery temp lt Setpoint ch high Par 1 Ch high hist on Par 19 Delivery temp lt Setpoint ch low Par 3 Ch low hist on Par 26 The burner shuts off when Delivery temp gt Setpoint ch high Par1 Ch high hist off Par 20 Delivery temp gt Setpoint ch low Par 3 Ch low hist off Par 27 ANALOGUE TEMPERATURE INPUT Par 14 3 Par 22 3 for low temperature circuits The following rules apply to high temperature low tempe rature circuit demand 0 2Vdc no demand by the high temperature low tempe rature circuit 2 9Vdc the heat demand is converted into a power de mand for each Slave using the algorithm PID_CH_ high CH 2V corresponds to a setpoint equal to T Ch high foot Par 18 T Ch low foot Par 24 9V to a setpoint equal to SetPoint Ch high Par 1 SetPoint Ch low Par 3 The setpoint is cal culated linearly between 2V and 9V Hysteresis for the end of demand is 0 2V and therefore demand is present above 2V and stops below 1 8V 907 80 70 60 50 40 30 20 10 Setpoint 0 1 2 3 4 5 6 7 8 9 10 Voltage Volt The burner ignited when Delivery temp lt Se
45. arly checked for the installation to always be at a higher pressu re than that of the atmosphere at any point compri sing the pump suction side and under all running conditions all the water sealing and couplings in the installation are designed to resist pressure towards outside but not for depression that the installation will not be made with materials permeable to gas e g plastic pipes for floor systems without anti oxygen barrier AN Lastly we would remind you that the warranty does not cover breakdowns incurred by the boiler due to deposits and corrosion 41 Appendix DECLARATION With regard to the fulfilments specific in chapter R 3 B of collection R the following is declared The Power Plus Box Beretta devices are modular premixed condensing heat generators for heating fully managed by a microprocessor Due to their design and structure they can be used as modules for the creation of high capacity heat generators with the purpose of having an optimal installed power both for overall system efficiency as well as in order to comply with environmental pollution standards In that regard as each heating element or module has all the devices foreseen by the provisions in R 3 F of collection R transmitted by ISPLELS memorandum no 102 99 dated 13 12 99 taking into account the positive results of the checks and tests carried out at the manufacturer s laboratory we believe that multiple elements or modules spe
46. at modular system stops completely when tur ning the main system switch to off Electrically power the modular system by turning the main system switch and the main device switch to on ON After few minutes of continuous operation with demand from the room thermostat the binders and manufacturing residuals will have evaporated and the following can be performed supply gas pressure check combustion check SUPPLY GAS PRESSURE CHECK Turn the main system switch off open the two front doors in the casing unscrew the pressure tapping point screw 3 located upstream of the gas valve by two turns and connect a pressure gauge there electrically power the system by turning the main sy stem switch and the main device switch to on In TEST mode it is possible to generate a high temperature heating demand at maximum power Proceed as follows press the Set esc and lt buttons at the same time for 5 seconds generate the heat demand using the room thermo stat The system will operate at maximum power in dicating H on the display followed by the delivery temperature flue cleaning function with the burner ignited at maximum power check that the gas pressure is the nominal supply pressure indi cate
47. be stored carefully and must ALWAYS accompany the boiler even if it is sold to another Owner or User or transferred to another plant If it is damaged or lost request another copy from your lo calTechnical Assistance Centre Beretta 1 2 Precautions The operation of any appliance that uses fuel electrical power and water demands that a number of fundamental safety precautions be respected e Do not allow children or infirm persons to operate the System unsupervised It is forbidden to use electrical devices or equipment such as switches appliances etc if there is a smell of gas or un burnt products If so ventilate the room opening doors and windows close the fuel shut off cock report the fault immediately to the Beretta s Technical Assistance Centre or a professionally qualified hea ting engineer Do not touch the boiler while barefoot or wet Never clean or service the boiler without first discon necting it from the mains electricity supply by turning the main power switch and the control panel switch OFF e Do not tamper with or adjust the safety or control de vices without prior authorisation and instructions from the manufacturer e Never pull disconnect or twist the electrical cables coming from the boiler even if it is disconnected from the mains electricity supply e Do not obstruct or restrict the vents in the room where the boiler is installed Adequate ventilation is essen tial for correc
48. cified above installed individually or in a series in any combination of the models indicated above can be considered as a single heat generator and the safety protection and control devices specified in chapters R 3 A and R 3 B of collection can be located within 1 metre of the hot water circuit delivery pipe immediately downstream of the last element or module The safety valve with the CE marking according to directive 97 23 EC will be installed directly on each module by the manufacturer on the delivery manifold and therefore does not require any additional safety valve downstream of the last module Beretta 57 58 X 59 N peretta Via Risorgimento 13 23900 Lecco LC Italy Customer Service 199 13 31 31 www berettaclima it The manufacturer strives to continuously improve all products Appearance dimensions technical specifications standard equipment and accessories are therefore liable to modification without notice 20076755 Rev 8 10 13
49. ction of the Slave cards access the Master card identify the connector at terminal J14 and disconnect it 4 3 2 1 MC BUS J14 MASTER card J2 2 Access to the SLAVE cards and setting the addresses every Slave card 3 or 4 per installed generator must be configured correctly to be recognised in the cor rect sequence by the Master card LAVE address O NOT CHANGE gt 440 NO ____ 10 HB LOCK address SLAVE card O BE SET J17 6 Main Example of a cascading configuration with 1 system Power Plus Box 200 and 1 Power Plus Box 150 In this case there are two blocks the first consisting of four generators and the third of three Therefore two blocks must be configured respectively with addresses 1 and 2 The slave addresses J10 must not be changed FIRST modular system SECOND modular system POWER PLUS BOX 200 POWER PLUS BOX 150 D BLOCK ia cl MER Master Master Slave Slave Slave OFF Address for BLOCK 1 Address for BLOCK 2 BLOCK address table Microswitches 1 2 3 4 BLOCKS OFF OFF OFF OFF Emergency OFF OFF OFF ON 1st block 1st modular system OFF OFF ON OFF 2nd block 2
50. d in the table DESCRIPTION G20 G30 G31 Wobbe index 45 7 80 6 70 7 MJ m Nominal supply pres 20 28 30 37 mbar stop the heat demand press OK to exit TEST mode disconnect the pressure gauge and tighten the pres sure tapping point 3 upstream of the gas valve COMBUSTION CHECK electrically power the system by turning the main system switch and the main device switch to on ON d OFF In TEST mode it is possible to generate a high temperature heating demand at maximum power Proceed as follows press the Set esc and buttons at the same time for 5 seconds On Error E 15 at D O AZ Prog 35 36 Gy Beretta generate the heat demand using the room thermo stat The system will operate at maximum power in dicating H on the display followed by the delivery temperature flue cleaning function combustion can be checked by unscrewing the cap 4 and inserting the analyser sensor in the foreseen position once the check is complete stop the flue cleaning function by pressing Set esc stop the heat demand remove the analyser sensor and carefully retighten the cap 4 FAN SPEED The fan speed is controlled automatically based on the gas type and the length of the flue gas exhaust line L This information
51. e operations to perform Before performing any operation disconnect the electric power supply by turning the main system switch to off Close the gas shut off valve 3 15 Cleaning and removing internal components Before any cleaning operation disconnect the electric power supply by switching the main system switch to off ON OFF OUTSIDE Clean the casing the control panel the painted parts and plastic parts with cloths moistened with soap and water In the case of stubborn stains moisten the cloth with a 5096 water and alcohol mixture or specific products Access to the control panel and the internal modular system parts open the two front doors in the casing loosen the screw 1 and turn the main control pane 2 loosen the screws 3 turn the instrument panel 4 2 1 4 3 ROTATE 6 4 ROTATE atthis point it will be possible to access the termina board 5 the Master card 6 and the Slave cards 7 Once the maintenance operations are complete refit the components working in the opposite direction of what was described e Do not use fuels sponges impregnated with abrasive Accessing the Master solutions or powder detergents INSIDE Before starting internal cleaning operations close the gas shut off valves Close the syste
52. e Slave cards If the delivery temperature 90 C for 5s the slave card is blocked no 46 If the return temperature gt 80 for 5s the slave card is blocked no 47 If the flue gas temperature 80 C for 5s the slave card is blocked no 48 and the fan operates for 10 minutes at maximum The Slave card is able to protect the primary exchanger from the hazards of low water circulation both using a flow switch as well as checking the difference between the deli very and return temperatures Checking AT uses the parameter AT max preset to 35 and limits the burner power as follows if AT max 5 C gt AT gt AT max 10 C burner mo dulated if AT max gt AT gt AT max 5 C burner at minimum if ALT gt A T max burner off Furthermore the presence of a sensor stops the exchanger if the pressure inside the combustion unit goes below 0 5 bar 3 7 Setting addresses for cascade coupling If it is necessary to implement multiple modular systems with a cascading connection the second modular system onwards must be disconnected from the Slave cards so that all Slave cards are managed only by the master card of the first modular system PRIMO Sistema Modulare Master Slave Slave Slave SECONDO Sistema Modulare Slave TERZO Sistema Modulare Slave Slave Slave Slave Slave For the modular systems of the second onwards 1 Access to the MASTER card and disconne
53. ector close the delivery and return taps for the heating element ref 16 27 of the Structure chapter empty the heating element as described in the System fil ling and emptying chapter loosen the upper and lower ring nuts 14 and remove the circulator 15 Once the maintenance operations are complete refit the components working in the opposite direction of what was described Disassembling the fan open the two front doors in the casing disconnect the wiring 16 of the fan 17 unscrew the two screws 19 that fix the fan 17 to the air conveyor 20 use a box spanner to unscrew the four screws 18 that fix the fan 17 to the exchanger remove the fan 17 Once the maintenance operations are complete refit the components working in the opposite direction of what was described A Check that the gas connection is leak proof Disassembling and cleaning the burner and exchanger open the two front doors in the casing disconnect the wiring 16 of the fan 17 unscrew the two screws 19 that fix the fan 17 to the air conveyor 20 use a box spanner to unscrew the four screws 18 that fix the fan 17 to the exchanger remove the gasket 21 and remove the burner 22 remove the electrode support plate 23 check the condition of the electrode and replace it if necessary 51 52 Cy Bere
54. eed is adjusted automatically For every heating element disassemble the gas valve from the van unit loose ning the three screws 3 identify the gas passage hole with the relative gasket that in the case of natural gas does not have a diaphragm insert the diaphragm 4 marked with 6 5 without removing the gasket Only for the case if the boiler is supplied with a gas mixture that can cause ignition problems use the other diaphragm 5 marked with 6 75 refit the gas valve apply the adhesive 6 for G30 G31 supplied inside the kit on the crosspiece located inside the modular system and remove the one for G20 remove the gas label from the outside A Gruppo termico regolato per G30 G31 28 30 37 mbar Paese di destinazione A After installing the kit check the tightness of all con nections made Perform all the calibration operations described below in the Adjustments chapter 3 11 Adjustments The Power Plus Box system is supplied for operation with G20 natural gas according to what is indicated on the technical plate and was already adjusted in the factory by the manufacturer However if it is necessary to repeat the adjustments for example after non scheduled maintenance replacing the gas valve or after transformation from G20 gas
55. ermanently ventilated rooms in compliance with the currently applicable Technical Regulation In this case a suitable system must be prepared for collecting conden sate and for flue gas exhaust see the specific chapter Flue gas evacuation for installations in central heating plants A Take into consideration the space that is required in order to access the safety and control devices and to perform the maintenance operations If possible maintain a distance of approx 1 metre between the rear panel and the wall Note that the front doors can be removed easily A Check that the electrical degree of protection of the modular system is suitable for the characteristics of the installation location 2 6 Installation in older systems and systems requiring modernisation If the system is being installed in an old or refurbished sy stem check that if installing in a central heating plant the flue is sui table for the condensing equipment at the tempera tures of the products of combustion calculated and built according to standard it is as straight as pos sible air tight isolated and not have obstructions or constrictions the flue has a connection for condensation evacua tion 23 24 Gy Beretta the electrical system has been implemented by qua lified personnel in compliance with the specific stan dards the flow rate head and flow direction of the circula tion pumps is appropriate
56. fan unit turning it anti clockwise the CO2 value decreases in order to obtain a value of 9 0 for G20 and 10 496 for G30 G31 CHECKING THE CALIBRATION Press the Set esc and buttons at the same time for 5 seconds and check the max CO2 value 9 0 G20 and 10 496 for G30 G31 The press the Set esc and lt buttons for 5s and check the minimum CO2 value 9 0 for G20 and 10 4 for G30 G31 When the checks are complete stop the flue cleaning function by pressing the button stop the heat demand remove the analyser sensor and carefully retighten the cap 1 3 12 Temporary shutdown In the case of temporary absences weekends short trips etc proceed as follows set the room thermostats to approx 10 C set parameter 2 to 10 or adjust the boiler thermostat to 10 C With the electric power supply remaining active as signal led by the flashing green LED and the supply of the gas the modular system is protected The electronic control unit has b active antifreeze pro tection b also in stand by mode There are two levels of antifreeze protection the first activates the pump if the manifold temperature lt 5 C or with CH type 1 and the outdoor sensor connected if the outdoor temp lt 3 C Par 35 Frost protection the high temperature circuit pump and system pump third pump are activated the second tha
57. fferential water and minimum pressure switch Return detection tap Safety valve 5 4 bar 1 7 Coupling configuration 58 T PSS SSS beue eem eR COMPENSATORE IDRAULICO POWER PLUS BOX 200 COMPENSATORE IDRAULICO ET 4 H SEC eni 4 e ui gt a Ne n dv m o a eil e iccssssss destano 8 gt lt o eo 1 3 L bol V 1 1 n Delivery manifold sensor SZ1 SZ2 SB Low system temperature sensor Boiler sensor Outdoor sensor SE Zone 1 circulator high temperature Zone 2 circulator low temperature PZ1 PZ2 NOTE it is possible to couple up to a maximum of 4 Power Plus Box with a cascade connection o 9 amp 5 gt 9 5 gt mm as V 1 8 Technical data Power Plus Box
58. fficiency The gas comburent air mixture is formed upstream of the burner due to the coupled modulating fan with a large pressure difference which intakes air from outside based on the system s heat demand as well as the pneumatic regulator that supplies the quantity of gas required for op timal combustion based on the quantity of aspirated air The flue gas produced by combustion passes through the numerous interspaces created by a winding with a bime tallic copper steel corrugated coil that encounters a spe cial cylindrical turbulator which stops the free outflow and constrains it to come into contact in counter current with the pipe in which the system return pipe passes By installing the individual heating elements in series not only permits classical ignition rotation but can also be set up so that when the first element reaches a certain power percentage the other subsequent elements will start alrea all with the same load factor The modular systems can be cascade connected up to 4 placing the antivibration couplings between the de livery return and gas manifolds accessories and the polypropylene coupling pipes for the flue gas manifold and the condensate outlet manifold supplied The flue gas evacuation and condensate outlet mani folds can have an outlet to the left or to the right Power Plus Box 115 HI 150 EXT Base module consisting of 3 heat generators for heating and DHW production systems Heat
59. h low If the outdoor temperature Tout max Par 38 preset to 18 C then setpoint T ch high foot Par 24 preset to 50 The setpoint is calculated linearly between the 2 outdoor temperature values Preset to 0 3 T out correct Outdoor temperature correction parameter 39 Normally the displayed value is the value read by the mi crocontroller plus or minus a correction value T visualizza ta T read by the sensor correction The read value of the outdoor temperature can be cor rected by varying the value of parameter 39 the permitted limit for the correction is 30 In this phase it is sug gested to use a reference thermometer Preset to 0 4 4 frost protection Antifreeze protection parameter 35 The electronic control unit has active antifreeze protection also in stand by mode The antifreeze protection has two levels the first that activates the pump and the second that activates the pump and the burner If the manifold temperature 5 C the high temperature circuit pump and the system pump third pump are active or with CH type 1 and outdoor sensor connected if the outdoor temperature lt 3 C par 35 the high tempe rature pump and the system pump third pump are active If after 10 the manifold temperature lt 5 C a burner is on at maximum until the manifold temperature gt 20 If after 10 manifold temperature gt 5 C but with _ type 1 Par 14 or 2
60. he other two are managed by the PID regulator If the manifold temperature gt Setpoint 2 the last bur ner ignited is shut off the remaining last two burners are managed by the PID regulator and the others operate at maximum power The Master control unit waits 30s before making another decision MODE MAXIMUM QUANTITY OF BURNERS IGNITED PAR 33 1 All burners are controlled by the same PID regulator which controls the manifold temperature and the setpoint is that of the active circuit high or low temperature circuit setpoint or DHW setpoint If the manifold temperature lt Setpoint 5 C the next bur ner is ignited The Master control unit waits for 305 and then if the manifold temperature lt Setpoint 5 C another burner is ignited If the manifold temperature gt Setpoint 2 C the last burner ignited is shut off The Master control unit waits 305 before making another decision ADDITIONAL CASCADING MANAGEMENT FUNCTIONS Sequential rotation of burner ignition When supplying power to the Master control unit the bur ner with address 1 is the first in the sequence After 24h the first burner will be the one with address 2 whereas the one with address 1 will become the last in the sequence Ignition shut off limitation In both cascading strategies after every ignition or shut off there is a minimum time during which the Master cannot ignite or shut off burners Quick start up and shut off I
61. he automatic bleed valves located at the top of every heating element Check that the valve cap is open EMPTYING Before emptying d isconnect the electric power supply by switching the main system switch to off ON OFF Make sure that the filling tap 4 insta system is closed led on the hydraulic 31 EMPTYING THE HEATING ELEMENT the hydraulic circuit pressure when cold is approx Close the diverting valve 1 and the return tap 2 for 1 5 bar and the circuit has been deaerated the heating element connect a plastic pipe to the heating element s drain tap 5 and open it A Before opening the drain tap 5 protect the under lying electric devices from the existing water 1 the system expansion tank preload is sufficient E 5 the electric connections have been made correctly IE i ZN It is mandatory to connect the circulators using con tactors with manual emergency actuation make sure that the bleed valve cap s have been un screwed the circulators can rotate freely unscrew the in 9 Spection screw and use a flat screwdriver to check that the main shaft moves without obstructions AN Before loosening or removing the circulator cap pro tect the electric devices located underneath from any SYSTEM EMPTYING water
62. igh foot 10 1 50 outdoor temperature Par 38 High temperature circuit ignition hyste 19 CH high hyst on 0 20 y C tesis o High temperature circuit shut off hyste 20 CH high hyst off 0 20 3 C resis 21 Attenuation_high 0 70 0 C Setpoint attenuation with TA open 0 Fixed temperature 22 CH type low 0 3 4 1 Weather with probe outside 2 0 10 power 3 0 10 temperature lower upper factory T N Name limit limit settings U M Description 23 T CH low limit 10 70 50 C Limit for low temperature circuit user set o Min low circuit setpoint at maximum 24 T CH low foot 10 Par 13 25 outdoor temperature Par 38 25 Attenuation low 0 70 0 C Setpoint attenuation with TA open o Low circuit ignition hysteresis calculated 26 CH low hyst on 0 20 5 C on mix delivery T Low circuit shut off hysteresis calculated 27 CH low off 0 20 3 C on mix delivery T Mix valve step At every step the valve opens 1 2 the 28 open time 0 255 5 ii set value Mix valve step clo At every step the valve closes 1 2 the 29 se time 299 d set value 0 255 5 s Mi valve wait time 31 Mixing p hyst 0 255 2 C Hysteresis for Maximum valve opening 32 Mixing_still_hyst 0 255 2 C 0 Minimum number of burners 33 Power control mode 0 1 1 Maximum number of burners 0 System loop 3rd pump 0 1 0 1 Low temperature circuit 35
63. input from 15 to 115 kW mod 115 HI Heat input from 15 to 135 kW mod 150 Power Plus Box 200 EXT Base module consisting of 4 heat generators for heating and DHW production systems Heat input from 15 to 180 kW 1 4 Safety devices The Power Plus Box modular system is equipped with the following safety devices installed on every heating ele ment Safety thermostat with automatic reset which when trip ped at 90 shuts off the burner Hydraulic circuit diagnostics the minimum flow rate of the carrier fluid for every heating element is controlled by a differential water pressure switch and an electronic safety System that controls a delivery sensor and a return sensor The equipment is protected if there is no water or in the case of insufficient circulation Safety valve for the heating system pressure which trips draining the system if circuit pressure exceeds the limit 5 4 bar Flue gas evacuation safety the flue gas sensor located at the bottom of the exchanger provokes a fault in the case of high flue gas temperature gt 80 Furthermore the check valve present in the flue gas exhaust line prevents the flue gas from passing between heating elements Fan safety the fan speed is always monitored by a Hall ef fect speed indicator device The Power Plus Box modulating systems are prepared for cascade coupling and this makes it possible to implement compact and extremely fle
64. ion of conformity confirming that the installation has been completed to the highest standards in compliance with the instructions provided by Beretta in this in struction manual and that it conforms to all appli cable laws and standaras This product must only be used for the purpose for which it is designed and made as specified by Beretta Beretta declines all responsibility contractual or other for damage to property or injury to persons or animals caused by improper installation adjustment maintenance or use In the case of water leaks disconnect the modular condensing system from the mains electrical supply close the water supply and promptly inform the Tech nical Assistance Centre Beretta or professionally qua lified personnel Periodically check that operating pressure in the wa ter circuit is over 1 bar but below the maximum limit specified for the boiler If this is not the case contact Technical Assistance Centre Beretta or a professionally qualified heating engineer The following operations shall be necessary if the boi ler is not used for a long period of time switch the boiler OFF at the control panel switch the boiler OFF at the mains power switch close the fuel cock and heating circuit water cock drain the central heating circuit if there is any risk of freezing Maintenance must be performed on the boiler at least once a year This manual is an integral part of the equipment and therefore must
65. ions that you MUST NOT do This booklet code 20076755 Rev 8 10 13 comprises 60 pages 3 1 3 2 3 3 3 4 3 5 3 6 3 7 3 8 3 9 3 10 3 11 3 12 3 13 3 14 3 15 3 16 4 1 COMMISSIONING AND MAINTENANCE 33 Initial Startup i 33 Checks during and after initial start up 34 Adjusting the functional parameters 36 Setting the heating parameters 37 Setting the DHW parameters 38 Heat control 38 Setting addresses for cascade coupling 42 Fault codes cesso se eR mx RR 44 List of 46 Transformation from one gas type to another 48 AGJUSTIMENTS al acida etate DRE TUS e 48 Temporary shutdown 49 Preparing for extended periods of disuse 49 50 Cleaning and removing internal components 50 Troubleshooting eee 5 WATER IN CENTRAL HEATING SYSTEMS 55 PAOD SINK tote nte etre ei tte ch tn ENDS oar 57 Gy Beretta GENERAL INFORMATION General information After removing the packaging check the condition and completeness of the supply If there are any problems contact the company Beretta that sold the equipment This product must be installed by a legally qualified heating engineer On completion of the installation the installer must issue the owner with a declarat
66. is managed by parameter 36 To make the change access INSTALLER PROGRAMMING mode fol lowing the procedure described in the User interfa ce chapter and set parameter 36 to 01 natural gas and L 15 m 02 natural gas and gt 15 m 03 LPG and L 15 m 04 LPG L 15 m ThePower Plus Box systems are supplied for operation with G20 natural gas with a flue gas exhaust line with L 15m parameter 36 1 1 A All checks must be performed by Technical Assistan ce Centre 3 3 Adjusting the functional parameters The heating functions can be set for the high temperature low temperature and DHW circuits based on the system requirements by setting the functional parameters The first three parameters can be accessed on the user level The next three require a password 22 see the IN STALLER PROGRAMMING mode chapter in the User interface chapter To access the user parameters press the 42 button and the following values will be displayed in order manifold delivery temperature T1 DHW temperature T3 low temperature circuit delivery temperature T6 To change the relative setpoints press the Set esc button the relative value will ap pear the two digits on the right will flash press lt and lt until obtaining the required value Press to save the new value The displayed va lue will stop flashing after 3 sec and will be operative A detailed description of all the
67. kly Combustion Check the combustion controls Check for the presence of 230Vac The burner does not start upon c n Gas valve voltage on the gas valve terminals sent of the modular system control check wiring and connections The modular system does not start No electric power supply no messa ge on the display Check the electric connections Check the condition of the fuse The modular system does not arrive at temperature Boiler dirty Clean the combustion chamber Burner capacity insufficient Modular system adjustment Check and adjust the burner Check correct functioning Check the temperature setting The generator triggers a thermal safety block No water Check correct functioning Check the temperature setting Check the electrical wiring Check the position of the sensor bul bs Modular system adjustment Check the bleed valve Check the heating circuit pressure The generator is at temperature but the heating system is cold Presence of air in the system Bleed the system Pump malfunctioning Check unseize the pump Replace the circulator Check the electrical connection of the circulator 53 54 Cy Beretta FAULT CAUSE SOLUTION The circulator does not start Pump malfunctioning Check unseize the pump Replace the circulator Check the electrical connection of the circulator
68. l casing Make the connections as shown in the diagram on the following page referring to the wiring diagrams Provide a three pole cable 8 to supply the 230V 50Hz line direct it through the hole made in the casing of the electric panel and connect it to the switch 9 as indicated on the wiring diagrams d A If coupling multiple modular systems with a cascade connection a power supply cable must be provided for each modular system A Beretta TERMINAL BOARD INSIDE THE CONTROL PANEL NTC TE D 5 pg 521 n IDO 27 DHW circulator VN zone 1 sensor m 3 ne System circulator SB Boiler sensor m 25 High temperature 4 i SQ Puma 24 5 NTO D PZ2 System circulator Lon e O O 23 Low temperature zone 2 sana vies Valv Mix NTC 268 EM que VM External sensor OFF de 2n Mixer valve 8 rem 2 1 19 Alarm signalling Room thermostat Room thermostat S TI T contact Low temperature High temperature IA s Analogue CR 5 Remote input 0 10V control ia ig 3
69. lve individual unit on off E e g fig circulator on then circulator off OC 8 Maximum ionization current range from to 99 at first attempt n n E g fig Maximum ionization current value on display 80 B Hours worked by unit from 0 to 9999 hours 9 E g fig 8050 hours first thousands and hundreds then tens and h B a Dh 5 units will appear in succession and coupled on the display 1 13 5 Installer programming mode The installer parameters can be changed by entering the password 22 The installer level password makes it possible to view and change the user and installer parameters Procedure for accessing the programming mode POS PROCEDURE DISPLAY Manifold delivery temperature T1 n 1 e g T1 80 C 180 3 1 IATL H n n 2 Press Set esc and OK After 5s the second and third digits will flash OL OL 3 Use and lt to enter the second number of the password the right digit p 2 8 4 E g password X2 ru 4 Press to save the second number of the password ru Use amp and lt to enter the first number of the password the central digit 5 E g password 22 EJ 6 Press OK to confirm the password if the password is incorrect the card returns to the O m 5 Display mode If it is correct the first parameter is displayed Ey I UD Press and lt to scroll the parameters en
70. m taps open the two front doors in the casing and access the inside of the control panel see the steps described above remove the screws 8 and then the rear cover 9 of the control panel for possible substitutions remove the 5 wiring connectors and unscrew the fastening screws to re move it A If replacing the Master card refer to the wiring dia gram when restoring the connections Once the maintenance operations are complete refit the components working in the opposite direction of what was described Accessing the Slave cards open the two front doors in the casing and access the inside of the control panel see the previously de scribed steps remove the screws V and then the upper cover 10 of the Slave card relative to the first heating element To access the other Slave cards repeat the same operation referring to covers 11 12 or 13 for possible substitutions remove the card s wiring connectors and unscrew the fastening screws to re move it A If replacing the Slave card refer to the wiring diagram when restoring the connections Once the maintenance operations are complete refit the components working in the opposite direction of what was described Disassembling the circulator open the two front doors in the casing disconnect the electric power supply conn
71. mperature values and operating status of the various circuits Press the button to scroll forward and view the values set for the individual circuits The values listed below will be displayed in succession by pressing the button POS VISUALIZED VALUES DISPLAY 1 T1 B 80 e g me 50 C 3 50 3 M cpu T4 4 BA 4 Flow temperature 2nd system or low T6 system 5 50 5 1st system room thermostat off or on e g OFF contact open ON contact closed J OE 6 2nd system room thermostat off or on e g OFF contact open ON contact closed Lj 0 10V analogue input atc d e g 5 5V 10V respectively 55 10 co 05 co 8 Mixer valve function status e g closing opening pause 9 Principal circulator function status e g circulator OFF circulator ON respectively 10 iJ ULI 10 Function status hot water system circulator P e g circulator OFF circulator ON respectively U 11 Second circulator function status P P e g circulator OFF circulator ON respectively J To exit the value display press the button If no operation is performed within 5 minutes the card will automatically return to display mode 18 Cy Beretta 1 13 3 Changing the user parameters Pressing displays the following values in succession manifold delivery temperature T1 DHW temperature T
72. n both modes there is a quick start up and shut off fun ction If the manifold temperature lt Setpoint 70 C the burners are ignited at time intervals equal to 2s If the manifold temperature gt Setpoint 4 C the burners are shut off at time intervals equal to 25 Low load The low load function prevents burner ignition and shut off in the case of a low heat demand The conditions for low load operation activation is controlled in every Slave card that sends the function activation request to the Master During normal operation the setpoint of the active circuit high or low temperature circuit setpoint or DHW setpoint is sent to the Slave cards and is controlled by the tempera ture of the heating element by every Slave card if the modular system temperature gt Setpoint 8 C or if the modular system temperature gt 85 C 8 C consent for starting the burner is not given If the Slave board acquires a modular system temperature greater than 85 C for 3 times with the burner ignited the heating element is turned off and the ignition procedure is started again Emergency function In the case of a Master card fault there are two methods for manually controlling the Slave cards With eBUS and with the manifold sensor Disconnect the power supply from the system di sconnect the BUS Set the address 000000 on all slave cards J10 and J17 OFF Connect a power supply between 21 and 28 Vac to the BUS If the manif
73. nd modular system OFF OFF ON ON 3rd block 3rd modular system OFF ON OFF OFF 4th block 4th modular system 43 44 Q Beretta 3 8 Fault codes MASTER CARD ERRORS The following tables provide a description of possible Master card errors The errors can be divided into two groups permanent type A errors which can only be turned off by pressing the reset button see ref 22 in the Control pa nels chapter type E block errors that turn off when the cause that determined them has disappeared Permanent type A errors No on the PC Cause Troubleshooting A16 10 Internal error Replace the Master card A18 12 Internal error Replace the Master card A20 14 Internal error Replace the Master card Type E errors that deactivate automatically owing errors that deactivate automatically can occur The fol If any of these errors is detected the red LED turns on see ref 15 in Control panels chapter NTC3 boiler sensor No on the PC Cause Troubleshooting E25 0 Internal error Replace the Master card E23 28 Internal error Replace the Master card E24 29 Internal error Replace the Master card E25 30 Internal error Replace the Master card E26 31 Internal error Replace the Master card Check that the bipolar switches of the individual units ae ON heck the addresses on the slave E32 9m Slaves not present Check the
74. nd tubes Micro corrosion phenomena may be triggered off owing to the difference in electrochemical potential coming to be created between the material in contact with the impurity and the surrounding one 55 56 Gy Beretta 3 2 Stray current corrosion Corrosion from stray currents can occur due to the differing electrical potentials between water in the boiler and the metallic mass of the boiler or piping This process leaves unmistakeable traces i e small regular conical holes AN All metallic parts should be grounded by an efficient earth cable for this reason 4 Eliminating air and gas from central heating systems If oxygen enters a circuit continuously or even intermittently e g in under floor heating systems whose pipes are not protected by impermeable synthetic sheaths in circuits with open expansion vessels or in circuits that require fre quent top ups always separate the boiler s water circuit from the central heating circuit Mistakes to avoid and precautions From what we have seen it is therefore important to avoid two factors possibly leading to the above mentioned pro cesses i e contact between air and water in the installation and regular topping up with fresh water To eliminate contact between air and water and to prevent the latter from becoming oxidized it is necessary for the expansion system to be a closed vessel type correctly scaled and with the correct pre loading pressure to be regul
75. nnector E39 39 Flue gas sensor with contact open Replace the flue gas sensor E40 40 The frequency is not 50 Hz Check the frequency of the electrical network E41 41 Internal error Replace the Slave card Check the delivery sensor connector E42 42 Flow sensor in short circuit Replace the delivery sensor Check the delivery sensor connector E43 43 Delivery sensor with contact open Replace the delivery sensor ALIE Check the return sensor connector E44 44 Return sensor short circuiting Replace the return sensor Check the return sensor connector E45 45 Return sensor with contact open Replace the return sensor E46 46 Delivery sensor error due to excee Check the correct flow rate in the water circuit of the indi ding the limit temp vidual unit 2 m h per unit E47 47 Return sensor error due to exceeding Check the correct flow rate in the water circuit of the indi the limit temp vidual unit 2 m h per unit Flue gas sensor error due to excee Check the correct flow rate in the circuit of every unit E48 48 ding the limit temp fan turns at max Approx 2 m h per unit with this error Clean the water side and flue gas side exchanger E49 49 Insufficient or absent earth con Check the earth connection Replace the Slave card 45 46 Cy Beretta 3 9 List of parameters lower upper factory N Name limit limit settings U M
76. o manage the power delivered by the system it is possible to se lect between the minimum and maximum quantity of lit burners 1 13 User interface master The exhaust function the high and low temperature circuit pumps remain in operation for 5 minutes after the last burner is turned off The waiting time before the heating element circulator is stopped once the burner is shut off is 6 minutes When the last burner is turned off the circulator only stops when the room thermostat demand stops he ignition shut off control function in both casca ding management modes there is a burner ignition and shut off limitation function in the case of low heat demand he system anti freeze protection function the Power Plus Box condensing systems are equipped with fre eze protection electronics The electronics activate the heating unit if the temperature drops below the minimum threshold Therefore the use of particular anti freeze fluids are not necessary except in the case of uses with the equipment completely shut off for long periods If using anti freeze fluids make sure they are not aggressive for steel The Power Plus Box system control panel buttons have different functions depending on the mode For example a combi nation of two buttons corresponds to a single function Or a function is activated by pressing the button briefly or waiting approx 5 seconds Reset Serves to release the electric board afte
77. of condensed steam and gas pursuant to the current regulation UNI EN 1443 The connection sections between the chimney and the boiler must have a minimum slope of 3 towards the boiler so that any condensate that forms in this line section can be evacuated using a suitable exhaust device The Power Plus Box modular condensing systems have been approved complete with a flue gas evacuation line in self ex tinguishing PP or suitable materials based on EN 677 and correlated standards The flue gas exhaust system foresees the use of pipes with the diameters indicated in the table All of the indicated diameters refer to lines in self extinguishing polypropylene class B1 implemented with pipes with socketed connections or equivalent lines The maximum equivalent length of the flue gas evacuation lines is indicated in the table Each modular system is provided with 2 female socketed connections 160 mm for the exhaust of combustion products to the right and to the left Description Maximum useful Maximum equivalent Flue gas evacuation output kW length m line diameter mm Power Plus Box 115 HI 150 lt 150 60 160 Power Plus Box 200 200 60 160 Power Plus Box 115 HI 150 x 2 300 55 160 lt 350 55 160 bat lt 400 55 160 es lt 450 40 160 ens 500 30 160 T 550 30 160 TM 600 25 160 T 650 30 200 Tem 700 30 200 zit 750 30 200 Power Plus Box 200 x 4
78. oint at maximum outdoor temperature T out ma x par 38 preset to 18 C Preset to 40 and upper value limited by par 23 T ch low limit preset to 50 CLIMATIC CURVE LOW TEMPERATURE circuit 100 ce T CH Low foot requirement B Delivery temperature C2 T out max 20 10 T CH Low 0 25 20 15 10 5 0 5 10 15 20 External temperature Therefore it is possible to work with a fixed point or set a climatic curve on every circuit 38 Gy Beretta 3 CH Priority Heating priority parameter 16 If set to O the system will work without heating priority with the high temperature and low temperature circuits served in parallel If set to 1 the demand from the low temperature circuit is ignored and the relative pump remains off The low tem perature circuit demand is only accepted when the high temperature circuit demand is inactive Vice versa if set to 2 the low temperature circuit has priority Preset to 0 3 5 Setting the DHW parameters The following DHW parameters can be set 1 Setpoint DHW DHW setpoint parameter 2 This is the production temperature for DHW The maximum limit is indicated by par 8 T DHW limit pre set to 60 C Preset to 50 2 DHW Type Boiler type parameter 6 0 DHW service 1 Quick exchanger with sensor 2 Boiler with sensor 6 Boiler with
79. old temperature lt Temp Emergency Par 40 preset 70 C can be set between 10 and 80 C all the burners will operate at maximum power If the manifold temperature gt Temp Emergency 5 C all burners are off With PC Disconnect the system power supply disconnect the BUS and connect the PC interface The burner power can be sent to the Slave card directly with the PC In the case of error contact Technical Assistance Centre Heat demand management for the high temperature circuit with analogue input Par 1422 or The room thermostat for the high temperature circuit is ignored in the case of heat demand and the input signal is used for calculating the system setpoint temperature or power The analogue input see terminals 13 14 on the wiring dia gram on page 35 is only for the Master card and can also be used for the low temperature circuit Par 22 The analo gue input cannot be used for both circuits ANALOGUE POWER INPUT Par 14 2 Par 22 2 for low temperature circuits The following rules apply to high temperature low tempe rature circuit demand 0 2Vdc no demand by the high temperature low tempe rature circuit 2 9Vdc the heat demand is converted into a power de mand for each Slave A 2V input corresponds to mi nimum power 9V to maximum power Par 15 The power is calculated linearly between 2V and 9V Hy steresis for the end of demand is 0 2V and therefore demand is present above 2V
80. parameters and the factory preset values can be found in the Parameter list chapter 3 4 Setting the heating parameters The following heating parameters can be set 1 Setpoint T CH High High temperature circuit setpoint parameter 1 If the fixed point operating mode is set par 142CH type high 0 it is the target temperature If the climatic control operating mode is set par 1421 it is the maximum target temperature with minimum outdoor temperature T out 37 preset to 0 C parameter 18 T ch high foot preset to 50 C defines the minimum setpoint at maximum outdoor temperature T out 38 preset to 18 Preset to 70 and upper value limited by par 17 T ch high limit preset to 80 CLIMATIC CURVE HIGH TEMPERATURE circuit 100 T CH High foot 80 Max heat 8 requirement 70 T out min 60 50 40 30 20 M 10 T out max T CH High Delivery temperature 25 20 15 10 5 0 5 10 15 20 External temperature 2 Setpoint T CH Low Low temperature circuit setpoint parameter 3 37 If the fixed point operating mode is set par 22 CH_type_low 0 it is the target temperature If the climatic control operating mode is set par 2221 it is the maximum target temperature with minimum outdoor temperature T out min par 37 preset to 0 C parameter 24 T ch low foot preset to 25 C defines the minimum setp
81. r a permanent ar rest Set esc Set makes is possible to enter the parameter change mode and monitor mode for the single units C This is used to view the operating status of the various cir cuits managed by the Master card andy Are used to increase or decrease a certain value OK Press to memorize new values On Error E 68 o e Prog 1 13 1 Display mode The red error LED turns on in the case of faults that involve the permanent block of a heating element normal operation can be reset by pressing the Master or Slave reset button The green on LED indicates the presence of the electric power supply The 3 digits with seven segments display the system statuses SYSTEM STATUS DISPLAY No demand for heating or hot water n 3 E The two right hand digits display flow temperature T1 E g T1 30 uu Demand for 1st system or 1st and 2nd system simultaneously TY The two right hand digits display flow temperature T1 E g T1 80 uu Demand for hot water or simultaneous functioning p cune The two right hand digits display flow temperature T1 E g T1 80 L 9 The point after the first digit flashes ene Demand for 2nd system A B The two right hand digits display flow temperature T1 E g T1 80 LU GQ Antifreeze function 1 13 2 Display mode Te
82. ration can be checked easily using the pH indica tor cards available commercially They can be purchased from any pharmacy or store selling chemical products The condensate that exits must have a pH value between 6 5 and 9 If any deposits are found on the surface of the neu tralisation device during maintenance it is recommended to replace the granulate 2 11 Electrical connections Power Plus Box systems leave the factory completely wired and the only connections required are the electric power supply cable the room thermostats the outdoor sensor and the user circulators using the dedicated terminals Proceed as follows Switch the boiler OFF at the mains power switch open the two front doors in the casing loosen the screw 1 and turn the main control pane 2 loosen the screws 3 turn the instrument panel 4 Insider there is the low temperature delivery boiler sensor and the outdoor sensor to be connected 27 ROTATE 4 ROTATE identify the cable glands 5 located on the rear part of the modular system and use them to pass the pump sensor and electric power supply cables inside the modular sy stem 28 dentify the terminal board 6 located inside the electric panel and direct the pump and sensor cables 7 towards it through the holes made in the pane
83. s Resistive values of the sensors The connection cable between the outdoor sensor and the control panel must not have couplings If the se are necessary they must be watertight and sui tably protected Any channelisation of the connection cable must be separated by live cables 230Vac If the outdoor sensor is not connected set parame ters 14 and 22 to 0 R CQ T CC R CO R CO R CO TCC 8 RQ RCO 20 67739 1 28481 18 13062 37 6470 56 3426 75 1925 94 1137 19 64571 27279 19 12565 38 6247 57 3319 76 1870 95 1108 18 61568 1 26135 20 12090 6033 58 3216 77 1817 96 1079 17 58719 2 25044 21 11634 40 5828 59 3116 78 1766 97 1051 16 56016 24004 22 11199 41 5630 60 3021 79 1717 98 1024 15 53452 4 23014 23 10781 42 5440 61 2928 1669 99 998 14 51018 5 22069 24 10382 43 5258 62 2839 81 1622 100 973 13 48707 6 21168 25 9999 44 5082 2753 82 1577 101 948 12 46513 7 20309 26 9633 45 4913 64 2669 83 1534 102 925 11 44429 19489 27 9281 46 4751 65 2589 1491 103 901 10 42449 9 18706 2
84. slave BUS connection Replace the Master Replace the slave E34 42 Internal 50HZ error The main frequency is not 50Hz 202 51 1 Primary delivery sensor not connected or interrupted NTC1 delivery sensor y y pieg NTC3 open 204 53 NTC3 boiler sensor DHW sensor not connected or interrupted NTC1 short circuiting au E18 67 NTC1 delivery sensor Primary circuit delivery sensor short circuit E20 69 NTC3 short circuiting DHW sensor short circuiting SLAVE CARD ERRORS Slave error list manual reset see ref 6 in the Control panels chapter In the case of slave type errors with manual reset also the Slave reset button can be used Water side limit thermostat tripped gt 90 while the burner was on No on the PC Cause Troubleshooting Check that the gas tap is open Check for the presence of electric discharge between the two ignition electrodes Check the ignition cable 1 5 ignition attempts without success Do not open the gas valve Replace the electronic card Slave Make sure the float in the siphon is not stuck Make sure the module is not full of condensation Check that the VIC gas shut off valve was not tripped Clean the electrodes unsuccessu atemis due Replace he igniter plug Replace the ignition cable A04 4 Water side limit thermostat gt 90 C Poor circulation in the primary circuit tripping version SCHED
85. t activates the pump and burner if after 10 the manifold temperature lt 5 C a burner is ignited at maximum until the manifold temperature gt 20 if after 10 manifold temperature gt 5 C but with CH Type 1 and outdoor sensor connected the out door temperature lt 3 C the pump continues to ope rate until outdoor temperature is gt 3 C 3 13 Preparing for extended periods of disuse The following operations shall be necessary if the Power Plus Box modular system is not used for a long period of time loosen the screw 1 and turn the control panel 2 position the main switch of the modular system 3 and the main system switch to off and check that the green indicator light turns off 4 AN In this case the antifreeze system is deactivated Empty the heating and DHW circuit if there is a fre ezing hazard 49 50 Cy Beretta 3 14 Maintenance Period maintenance is mandatory required by Presiden tial Degree 26 August 1993 no 412 and is also essential for device safety efficiency and duration It makes it possi ble to reduce consumption polluting emissions and keep the product reliable over time Remember that device maintenance can be performed by Technical Assistance Centre or by professionally qualified personnel Remember that performing a combustion analysis prior to starting maintenance provides useful information about th
86. t combustion e It is prohibited to leave inflammable substances and containers in the room where the boiler is installed e Do not dispose of packaging material into the envi ronment or leave it within the reach of children since it can become a potential hazard Dispose of packa ging material in compliance with applicable legisla tion 1 3 Description of the appliance Power Plus Box is a modular premixed condensing system consisting of a set of 3 or 4 heating elements installed in series Every Power Plus Box system is closed in a steel plate con tainment structure made specifically for outdoor installa tion The design was studied to ensure rational use of spa ce and to make it easier to access the components during maintenance operations In addition to obtaining considerable fuel savings due to condensation Power Plus Box systems offer the possibility to avoid a central heating plant in installations where the systems can be positioned outside or on the roof of the building Depending on the model the heat input ref PCI of every modular system reaches 110 135 or 180 kW and can be modulated between 10 and 100 Efficiency reaches 107 796 100 ref PCI 50 C 30 C and the low flue gas temperatures make it possible to use a fully integrated plastic flue gas manifold The combustion system and the flue gas water heat exchange make it possible to reach very high levels of combustion and heat to water transfer e
87. to G30 G31 gas or vice versa proceed as described below A Adjustments to maximum and minimum power must be performed in the indicated sequence and only by Technical Assistance Centre A All the operations described below must be carried out for every individual heating element while opera ting only the heating element involved with the adjust ment and turning off other others using the proper switch see ref 8 11 in the Control panels chapter CO2 ADJUSTMENT AT MAXIMUM POWER Press the Set esc and lt buttons at the same time for 5 seconds use and lt to select the maximum fan speed generate the heat demand using the room thermo stat The modular system will operate at maximum power indicating H on the display followed by the delivery temperature flue cleaning function unscrew the cap 1 and insert the combustion analy ser sensor adjust CO2 using a screwdriver to turn the adju sting screw 2 located on the fan unit turning it clockwise the CO2 value decreases in order to obtain a value of 9 0 for G20 and 10 496 for G30 G31 CO2 ADJUSTMENT AT MINIMUM POWER Press the Set esc and lt buttons at the same time for 5 seconds use amp and lt to select the minimum fan speed The modular system will operate at minimum power in dicating L on the display followed by the delivery temperature adjust the CO2 using a screwdriver to turn the adju sting screw 3 located on the
88. tpoint ch high Par 1 Ch high hist on Par 19 Delivery temp lt Setpoint ch low Par 3 Ch low hist on Par 26 The burner shuts off when Delivery temp gt Setpoint ch high Par 1 Ch high hist off Par 20 Delivery temp gt Setpoint ch low Par 3 Ch low hist off Par 27 MIX VALVE MANAGEMENT The mix valve is controlled by the parameters Mix valve step open time Par 28 preset to 5s Mix valve step close time Par 29 preset to 7s Mix valve interval time Par 30 preset to 5s Mix valve p hyst Par 31 preset to 2 C Mix valve still hyst Par 32 preset to 2 C Before opening or closing the valve waits the period of time set in Par 30 Opens if T mandata bassa lt Setpoint low Par32 Closes if T mandata bassa gt Setpoint low Par32 Within the interval the valve remains in its current position If T mandata bassa Setpoint low Par31 opens for a period of time equal to half the value set in Par 28 If T mandata bassa gt Setpoint low Par31 closes for a period of time equal to half the value set in Par 29 41 Manifold temperature Apre Chiude Uhiusura Apertura Valvola S 25 30 35 40 45 50 55 60 Temperatura Mandata Mix C default 31 10 42 Cy Beretta Safety functions of th
89. tta Once the maintenance operations are complete refit the components working in the opposite direction of what was described A Check that the gas connection is leak proof Disassembling the doors In particular operations must be carried out inside the mo dular system the two front doors can be disassembled Proceed as follows open the two front doors working from inside remove the pin 24 and the door 25 Once the maintenance operations are complete refit the components working in the opposite direction of what was described 3 16 Troubleshooting FAULT CAUSE SOLUTION There is a smell of gas Gas supply circuit Check the seal of the gaskets and the closure of the pressure tapping points Odour of unburnt gas Flue gas circuit Check the gasket seals Make sure there are no obstructions Check the combustion quality Irregular combustion Burner gas pressure Check the temperature setting Diaphragm installed Check the diameter Clean the burner and exchanger Check the conditions Exchanger passages obstructed Check passage cleaning Faulty fan Check operation Ignition delays with pulsations to the burner The modular system becomes dirty Burner gas pressure Check the temperature setting Ignition electrode Check the positioning and conditions Check the flame colour very quic
90. ways greater than the union on the modular system A The connection to the drainage system must be made according to current laws in compliance with any local regulations A Fill the water pipes 1 for connecting to the con densate outlet manifold in order to avoid products of combustion from entering the environment during the first minutes of modular system ignition 1 pi ai A If installing in a central heating plant it is recommended to direct both the products deriving from the boiler con densate outlet as well as the condensate deriving from the flue gas manifold to the same exhaust outlet A The boiler base must be horizontal and flat in the area of the support frame to prevent problems with con densate evacuation A Any condensate neutralisation devices can be con nected after the siphon For the calculation of the duration of the neutralisation load the amount of neutraliser consumption must be evaluated after one year of operation The total duration of the load can be extrapolated from this information A Pay particular attention to fixing the condensate eva cuation pipe from the siphon located on the flue gas exhaust manifold and from the condensate outlet ma nifold gt
91. xible central heating plants than ks to the system s modulating ratio A The tripping of the safety devices indicates a poten tially hazardous malfunction of the modular system therefore contact Technical Assistance Centre imme diately Therefore it is possible to restart the system after waiting a brief period see the first start up chapter Gy Beretta e The modular system must not be operated even tem porarily if the safety devices are not functioning or have been tampered with AN The safety devices must be replaced by Technical Assistance Centre only using original components from the manufacturer Refer to the spare parts cata logue provided with the modular system After making the repair correct that the modular system is operating properly 1 5 Identification The products are identified by P O Beretta D C9 C9 mmm

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