Installation Manual. Power Plus Box THERMAL MODULES CONDENSING. Installation Manual

Transcription

1 Installation Manual Power Plus Box THERMAL MODULES CONDENSING EN Installation Manual

2 RANGE MODEL CODE POWER PLUS BOX POWER PLUS BOX ACCESSORIES For a coplete list of accessories and details of their copatibility, refer to the Catalogue. Dear heating engineer, Congratulations on having chosen a B boiler. You have selected a odern, quality product that is designed to give dependable, efficient and safe service and to provide cofort in the hoe for any years to coe. This anual provides inforation that is essential to the installation of the appliance. Used in conjunction with your own knowledge and expertise it will enable you to install the appliance quickly, easily, and correctly. Please accept our thanks and our congratulations on your choice of product. Beretta CONFORMITY The Power Plus Box odular condensing systes coply with: - Directive 009/4/EC - Gas Appliances - Directive 9/4/EEC on efficiency requireents and Annex E and Pres. Republic Decree n. 4, 6 August 99 (****) - Electroagnetic Copatibility Directive 04/0/EU - Low Voltage Directive 04//EU - Ecodesign Directive 009//CE for energy-related products - Delegated Regulation (EU) N. 8/0 - Standard for gas-fired heating boilers - General requireents and tests - EN 0- - Specific standard for type C appliances and type B, B and B appliances of noinal heat input not exceeding 000 kw - EN 0-/. Furtherore, odular condensing systes Power Plus Box fulfil the provisions of chapter R..B, collection "R" ISPESL. See annex. b This product ust only be used for the purpose for which it is designed and ade, as specified by B. B declines all responsibility, contractual or other, for daage to property or injury to persons or anials caused by iproper installation, adjustent, aintenance or use. ENGLISH

3 CONTENTS GENERAL INFORMATION General Safety Inforation Precautions Description of the appliance Safety devices Identification Syste layout Coupling configuration Technical specifications Water circuit Location of sensors Wiring diagras Control panels User interface (aster) Display ode Display ode Changing the user paraeters Monitor ode Installer prograing ode Test ode Error ode Peranent block COMMISSIONING AND MAINTENANCE.. 4. Initial startup Checks during and after initial start-up Adjusting the functional paraeters Setting the heating paraeters Setting the DHW paraeters Heat control setting Setting addresses for cascade coupling Error List Master board errors Slave board errors List of paraeters Transforation fro one gas type to another Adjustents Teporary shutdown Preparing for extended periods of disuse Maintenance Cleaning and reoving internal coponents....6 Troubleshooting WATER IN CENTRAL HEATING SYSTEMS 6 INSTALLATION Unpacking the product Opening Overall diensions and weights Handling Installation preises Installation in older systes and systes requiring odernisation Water connections Flue gas evacuation for installations in a central heating plant Condensate evacuation Neutralising the condensate Electrical connections Outdoor sensor installation Syste filling and eptying Preparing for initial startup The following sybols are used in this anual: b CAUTION! = Identifies actions that require caution and adequate preparation. a STOP! = Identifies actions that you MUST NOT do. This anual, Code - Rev. coprises pages. This anual, Code Rev. (0/6) coprises 60 pages.

4 4 GENERAL INFORMATION. General Safety Inforation b After reoving the packaging, check the condition and copleteness of the supply. If there are any probles, contact the copany B that sold the equipent. b This product ust be installed by a legally qualified heating engineer. On copletion of the installation, the installer ust issue the owner with a declaration of confority confiring that the installation has been copleted to the highest standards in copliance with the instructions provided by B in this instruction anual, and that it confors to all applicable laws and standards. b This product ust only be used for the purpose for which it is designed and ade, as specified by B. B declines all responsibility, contractual or other, for daage to property or injury to persons or anials caused by iproper installation, adjustent, aintenance or use. b In the case of water leaks, disconnect the odular condensing syste fro the ains electrical supply, close the water supply and proptly infor the Technical Assistance Centre B or professionally qualified personnel. b Periodically check that operating pressure in the water circuit is over bar but below the axiu liit specified for the boiler. If this is not the case, contact Technical Assistance Centre B or a professionally qualified heating engineer. b The following operations shall be necessary if the boiler is not used for a long period of tie: - Switch the boiler OFF at the control panel - Turn the ain syste switch "off" - Close the fuel cock and heating circuit water cock - Drain the central heating circuit if there is any risk of freezing. b Maintenance ust be perfored on the boiler at least once a year. b This anual is an integral part of the equipent and therefore ust be stored carefully and ust ALWAYS accopany the boiler even if it is sold to another Owner or User or transferred to another plant. If it is daaged or lost, request another copy fro your local Technical Assistance Centre B.. Precautions The operation of any appliance that uses fuel, electrical power and water deands that a nuber of fundaental safety precautions be respected: a Do not allow children or infir persons to operate the syste unsupervised. a It is forbidden to use electrical devices or equipent, such as switches, appliances, etc. if there is a sell of gas or un-burnt products. If so: - Ventilate the roo, opening doors and windows - Close the fuel shut-off cock - Report the fault iediately to the B's Technical Assistance Centre or a professionally qualified heating engineer. a Do not touch the boiler while barefoot or wet. a Never clean or service the boiler without first disconnecting it fro the ains electricity supply by turning the ain power switch and the control panel switch OFF. a Do not taper with or adjust the safety or control devices without prior authorisation and instructions fro the anufacturer. a Never pull, disconnect, or twist the electrical cables coing fro the appliance even if it is disconnected fro the ains electricity supply. a Do not obstruct or restrict the vents in the roo where the boiler is installed. Adequate ventilation is essential for correct cobustion. a It is prohibited to leave inflaable substances and containers in the roo where the boiler is installed. a Do not dispose of packaging aterial into the environent, or leave it within the reach of children, since it can becoe a potential hazard. Dispose of packaging aterial in copliance with applicable legislation.. Description of the appliance Power Plus Box is a odular preixed condensing syste consisting of a set of or 4 heating eleents installed in series. Every Power Plus Box syste is closed in a steel plate containent structure ade specifically for outdoor installation. The design was studied to ensure rational use of space and to ake it easier to access the coponents during aintenance operations. In addition to obtaining considerable fuel savings, due to condensation, Power Plus Box systes offer the possibility to avoid a central heating plant in installations where the systes can be positioned outside or on the roof of the building.

5 Depending on the odel, the heat input (ref. PCI) of every odular syste reaches 0, or 80 kw, and can be odulated between 0% and 00%. Efficiency reaches 07.7% (00% ref. PCI, 0 C-0 C) and the low flue gas teperatures ake it possible to use a fully integrated plastic flue gas anifold. The cobustion syste and the flue gas - water heat exchange ake it possible to reach very high levels of cobustion and heat to water transfer efficiency. The gas/coburent air ixture is fored upstrea of the burner, due to the coupled odulating fan with a large pressure difference, which intakes air fro outside based on the syste's heat deand, as well as the pneuatic regulator that supplies the quantity of gas required for optial cobustion based on the quantity of aspirated air. The flue gas produced by cobustion passes through the nuerous interspaces created by a winding with a bietallic copper/steel corrugated coil that encounters a special cylindrical turbulator, which stops the free outflow and constrains it to coe into contact, in counter-current, with the pipe in which the syste return pipe passes. By installing the individual heating eleents in series not only perits classical ignition rotation but can also be set up so that when the first eleent reaches a certain power percentage, the other subsequent eleents will start already, all with the sae load factor. The odular systes can be cascade connected (up to 4), placing the antivibration couplings between the delivery, return and gas anifolds (accessories) and the polypropylene coupling pipes for the flue gas anifold and the condensate outlet anifold (supplied). The flue gas evacuation and condensate outlet anifolds can have an outlet to the left or to the right. Power Plus Box 0 Base odule consisting of heat generators for heating and DHW production systes. Heat input fro to kw Power Plus Box 00 Base odule consisting of 4 heat generators for heating and DHW production systes. Heat input fro to 80 kw..4 Safety devices The Power Plus Box odular syste is equipped with the following safety devices, installed on every heating eleent: Safety therostat with autoatic reset, which, when tripped at 90, shuts off the burner. Hydraulic circuit diagnostics the iniu flow rate of the carrier fluid for every heating eleent is controlled by a differential water pressure switch and an electronic safety syste that controls a delivery sensor and a return sensor. The equipent is protected if there is no water or in the case of insufficient circulation. Safety valve for the heating syste pressure, which trips, draining the syste if circuit pressure exceeds the liit (.4 bar). Flue gas evacuation safety the flue gas sensor, located at the botto of the exchanger, provokes a fault in the case of high flue gas teperature (> 80 C). Furtherore, the "check valve" present in the flue gas exhaust line prevents the flue gas fro passing between heating eleents. Fan safety the fan speed is always onitored by a Hall-effect speed indicator device. The Power Plus Box odulating systes are prepared for cascade-coupling and this akes it possible to ipleent copact and extreely flexible central heating plants thanks to the syste's odulating ratio. b The tripping of the safety devices indicates a potentially hazardous alfunction of the odular syste, therefore contact Technical Assistance Centre iediately. Therefore it is possible to restart the syste after waiting a brief period (see the first start-up chapter).

6 (Laterale DX) 0684_E0 a The odular syste ust not be operated, even teporarily, if the safety devices are not functioning or have been tapered with. b The safety devices ust be replaced by Technical Assistance Centre, only using original coponents fro the anufacturer. Refer to the spare parts catalogue provided with the odular syste. After aking the repair, correct that the odular syste is operating properly.. Identification The products are identified by: Paese di destinazione: Tipo di apparecchio: B Caldaia categoria : IIH+ Teperatura abiente: in. -0 C ax. 0 C Pressioni di alientazione gas: G0 0 bar G0 8-0 bar G 7 bar Regolazione effettuata dal costruttore: G0-0 bar - H METANO ATTENZIONE Questo apparecchio puó essere installato e funzionare all'aperto o solo in locali peranenteente ventilati secondo nora UNI79. Leggere attentaente il libretto istruzioni pria di installare e ettere in servizio l'apparecchio. 6 Caldaia regolata per: G0 0 bar Paese di destinazione: ITALIA Gas label. It is applied on the front part of the device and indicates the type of gas used by the odular syste and the country of destination. Technical data plate It indicates the technical and perforance data. Serial nuber plate This is located on the boiler body and specifies the serial nuber, odel, and furnace power. b Spare parts and/or technical operation require the exact identification of the corresponding odel. The absence of, tapering with or reoving the identification plates or other does not ake it possible to reliably identify the product, akes any installation and aintenance operation difficult and invalidates the warranty.

7 .6 Syste layout Control panel Single heating eleent Control panel 4 Bus cable passage cable gland for the cascade connection Flue gas anifold 6 Gas anifold 7 Syste delivery anifold 8 Condensate drain anifold 9 Syste return anifold 0 Single heating eleent flue gas analysis outlet Fan Single heating eleent flue gas exhaust union Autoatic bleed valve 4 Safety therostat Drain cock 6 Manual diverting valve 7 Circulator (or -way valve) 8 Gas valve 9 Coburent air intake union 0 Gas cock Flow probe Ignition/detection electrode Exchanger 4 Return probe Exhaust flue probe 6 Differential water and iniu pressure switch 7 Return detection tap 8 Safety valve.4 bar 7

8 .7 Coupling configuration SE POWER PLUS BOX 00 COMPENSATORE IDRAULICO PZ SZ PZ VM PB SB SZ 80 C SE 60 C 0 C 8 POWER PLUS BOX 0 POWER PLUS BOX 00 COMPENSATORE IDRAULICO PZ SZ PZ 0 C VM PB SB SZ SZ SZ SB SE PZ PZ PB VM Delivery anifold sensor Low syste teperature sensor Boiler sensor Outdoor sensor Zone circulator (high teperature) Zone circulator (low teperature) Boiler circulator Mixer valve NOTE: it is possible to couple up to a axiu of 4 Power Plus Box with a cascade connection.

9 .8 Technical specifications MODEL Power Plus Box 0 00 Fuel G0 - G0 - G Device category IIH+ Device type B, B Furnace heat output ref. PCS (in - ax) 6,0-0 6,0-00 kw Furnace heat output ref. PCI (in - ax) 4,4-4,9 4,4-79,8 kw Useful heat output (80 /60 C), 76,6 kw Useful heat output (0 /0 C) 4, 9,6 kw Useful heat output (60 /40 C) 4, 90,8 kw Useful efficiency ref. PCI (80 C/60 C) 98, % Useful efficiency ref. PCI (0 C/0 C) 07,7 % Useful efficiency ref. PCI T=0 C (60 C/40 C) 06, % Useful efficiency at 0% ref. PCI (80 C/60 C) 98,7 % Useful efficiency at 0% ref. PCI (0 C/0 C) 08,7 % Useful efficiency at 0% ref. PCI T=0 C (60 C/40 C) 06,6 % Chiney loss with burner operating, % Chiney loss with burner off 0, % Casing loss (T=70 C) 0, % Flue gas teperature Return teperature + C C CO at iniu 9,0 (G0) - 0,4 (G0-) % CO at axiu 9,0 (G0) - 0,4 (G0-) % CO S.A. at iniu - axiu less than - 9 g/kwh NOx Class Maxiu heating operating pressure 6 bar Maxiu peritted teperature 90 C Boiler water teperature selection range (± C) 0-80 C Water capacity 0 l Power supply 0~0/60 V~Hz Maxiu electric power consuption W Electric degree of protection X4D IP Quantity of condensate at axiu power,6 8,8 kg/h CONNECTIONS Delivery anifold " DN - PN 6 Ø - DN Return anifold " DN - PN 6 Ø - DN Gas anifold " DN 80 - PN 6 Ø - DN Flue gas outlet 60 Ø Condensate outlet 0 Ø DIMENSIONS Height 00 Width 0 Depth 60 9

10 0 Detail Power Plus Box 0 00 Maxiu rated heat input 0 00 kw Miniu rated heat input 6,7 6,7 kw Doestic hot water axiu rated theral input (80-60) - - kw Doestic hot water iniu rated theral input (80-60) - - kw PARAMETER Seasonal heating energy efficiency class - - Water heating energy efficiency class - - Rated input Prated,6 76,8 kw Seasonal energy efficiency in central heating ode ηs 9, 9, % USEFUL HEAT OUTPUT at rated theral input and at high teperature rating P4,6 76,8 kw at 0% of rated theral input and at low teperature rating P 48,9 6, kw EFFICIENCY at rated theral input and at high teperature rating η4 88,4 88,4 % at 0% of rated theral input and at low teperature rating η 97,8 97,8 % ADDITIONAL ENERGY CONSUMPTION at full load El ax 40 0 W at partial load El in 7 96 W in stand-by PSB 6 8 W OTHER PARAMETERS Heat loss in standby ode Pstby W Energy consuption of the pilot light Ping - - W Annual energy consuption Q HE - - GJ Level of inner sound power LWA - - db Eissions of nitrogen oxides NOx - - g/kwh FOR COMBINATION HEATING APPLIANCES Declared load profile - - Energy efficiency in DHW ode ηwh - - % Daily electrical energy consuption Qelec - - kwh Daily fuel consuption Qfuel - - kwh Annual electrical energy consuption AEC - - kwh Annual fuel consuption AFC - - GJ

11 .9 Water circuit SF AA 8 9 AA AA GAS MI SC 4 0 RI Fan Autoatic bleed valve Burner 4 Heat exchanger Drain cock 6 Differential water and iniu pressure switch 7 Circulator (or -way valve) 8 Gas valve 9 Flue gas exhaust union with check valve and flue gas analysis outlet 0 Manual diverting valve Return shut-off valve Gas cock Delivery sensor traps 4 Safety valve AA Air inlet SF Exhaust flue duct SC Condensate outlet MI Central heating flow RI Central heating return GAS Gas supply

12 WATER SIDE PRESSURE DROP FOR EVERY HEATING ELEMENT Every heating eleent of the Power Plus Box odular syste is equipped with a circulator, whose perforance curve is provided below, in reference to speed heating eleent 000 Pressure drop (bar) Circulator characteristic curve P available for syste circulation Pressure lost by the fluid when crossing the heating eleent Flow rate (l/h) Heating eleent pressure drop at 000 l/h: 0 bar. Flow rate necessary for every heating eleent: 000 l/h. b At the first start-up, and at least once a year, the rotation of the circulator shaft should be checked as, especially after long periods of not being operated, deposits and/or residuals could ipede its free rotation. b Before loosening or reoving the circulator cap, protect the electric devices located underneath fro any water that exits. a It is prohibited to operate the circulators without water.

13 .0 Location of sensors SAFETY THERMOSTAT (triggering at 90 C) HEATING DELIVERY SENSOR SZ SZ SB SE PZ PZ PB VM Delivery anifold sensor Low syste teperature sensor Boiler sensor Outdoor sensor Zone circulator (high teperature) Zone circulator (low teperature) Boiler circulator Mixer valve HEATING RETURN SENSOR 80 C SE FLUE GAS SENSOR (triggering at 80 C) 0 C 60 C POWER PLUS BOX HYDRAULIC COMPENSATOR PZ SZ PZ 0 C VM PB SB SZ b Install sensors SZ and SB in a trap (outside the odular syste). Correspondence table for all sensors Measured teperatures ( C) - Resistive values of the sensors (Ω). T ( C) R ( Ω) T ( C) R ( Ω) T ( C) R ( Ω) T ( C) R ( Ω) T ( C) R ( Ω) T ( C) R ( Ω) T ( C) R ( Ω)

14 . Wiring diagras J6 J4 Fusibile 4A J7 J8 J gv gv gv 4 J a Circolatore a 6 F T Terra Terra Terra Fase Neutro 4 Ground star pole a a Ground star pole gv Neutro Terra Fase a gv al polo stella di terra g n v a J a b J n b v g J Valvola gas Terostato liite 4 6 Soffiante (+) Input Sens. Hall Alientaz. Sens. Hall J9 a J4 a a Coune Sens. Hall Soffiante (-) NTC andata NTC di ritorno NTC fui WD J T J6 gv Bus line with feale connector for possible connection to another slave card for an adjacent odular syste. PC Connection by the installer 0V~0Hz CS IG EA/ER SLAVE a 4 Pressostato Diff. 4 J0 4 J7 Main BUS IG C VG TS PD SM 6 SR SF 6 A B Bus Co. J9 8 7 J8 Valv.Mix 9 OFF NTC ON Alar NTC NTC Circ. NTC Circ. Analogic Input 6 J 4 T 4 BUS J4 4V Pup 8 7 J0 Pup 6 Pup 4 J Neutro Popa Sanit. Fase Popa Sanit. Neutro Popa circ. Fase Popa circ. Neutro Popa Fase Popa Neutro Valv. Mix Off - Valv. Mix On - Valv. Mix J0 J8 R6 R R4 R R Fuse F. A Fase 0V a.c. Neutro 0V a.c. a J Terra gv J7 Terra gv J6 Terra gv J MC Terra gv J4 R J J PC Alar Coune BARCODE J Coune J 4 J J J J 6 J 4 J 7 NTC cliatica Coune NTC and. circ. T. A. circ. Coune T. A. circ. Coune Analogic Input Coune Ebus contr. reoto 4V contr. reoto Coune Coune NTC bollitore Coune NTC and. circ. PB MASTER PZ PZ VM J 7 J 4 J 6 J J J J 4 J SZ SB SZ TA TA IA CR SE J J J 0 J J J 4 J 4 J 0 J J 9 J J 8 J J J0 6 J0 J0 4 J0 J0 J0 J9 J9 J9 J8 J8 7 4 J J 4 8 J0 6 J0 J0 4 J0 J0 J0 J8 J8 4 J8 J8 J8 MODULAR SYSTEM IG Modular syste ain switch CS Contact for external safeties PB Boiler circulator PZ Zone circulator (high teperature) PZ Zone circulator (low teperature) VM Mixer valve CR Reote control (accessory available separately) IA Analogue input SB Boiler sensor SZ Zone sensor SZ Zone sensor SE Outdoor sensor TA Zone roo therostat (high teperature) TA Zone roo therostat (low teperature) HEATING ELEMENT C Heating eleent circulator (or -way valve) SM Flow probe SR Return probe SF Exhaust flue probe TS Safety therostat VG Gas valve PD Water differential pressure switch EA/ER Ignition/detection electrode IG..IG4 FIRST...FOURTH heating eleent switch J0/J7 Addressing icroswitches

15 v v v v v v al polo stella di terra al polo stella di terra al polo stella di terra EA/ER IG EA/ER IG4 C EA/ER IG Terra Terra Terra Fase Neutro gv gv gv J6 J4 Fusibile 4A J8 J J7 Terra Terra Terra Fase Neutro gv gv gv J6 J4 Fusibile 4A J8 J J7 Terra Terra Terra Fase Neutro gv gv gv J6 J4 Fusibile 4A J7 J8 J a 4 F T a Circolatore 6 a 4 F 6 a a 4 F T Circolatore Circolatore 6 a J A C B J C J VG TS Valvola gas VG TS Valvola gas Valvola gas BUS BUS BUS 4 T g 8 a 7 J a g 8 b Terostato liite 4 J 7 a J a g 8 a J a b b Terostato liite Terostato liite VG TS n J b g Soffiante (+) Input Sens. Hall Alientaz. Sens. Hall Coune Sens. Hall Soffiante (-) n NTC andata a 6 NTC di ritorno J4 a 4 J9 0 NTC fui 9 a J6 WD J T PC SLAVE SM SR SF Main J0 J7 4 J 7 4 J WD WD Pressostato Diff. a Pressostato Diff. a n Pressostato Diff. a PD n PD PD J SLAVE 4 J SLAVE b b g Soffiante (+) Input Sens. Hall Alientaz. Sens. Hall Coune Sens. Hall Soffiante (-) J PC g Soffiante (+) Input Sens. Hall Alientaz. Sens. Hall Coune Sens. Hall Soffiante (-) J PC n T n T SM NTC andata SM NTC andata 6 a 6 NTC di ritorno a J4 a NTC di ritorno J4 a 4 J9 J0 SR SF 4 J9 J0 SR SF 0 0 NTC fui NTC fui 9 a J6 J7 9 a J6 J7 Main Main Bus line with ale connector for possible connection to another slave card for an adjacent odular syste. b The circulators ust be connected with the interposition of suitable contactors with anual eergency actuation.

16 . Control panels Electric power supply signal Master user interface Slave user interface 4 Slave card operating status signal: - FLASHES in absence of heat deand - FLASHES QUICKLY during the ignition cycle - ON in presence of a flae Single heating eleent block signalling: - OFF in absence of errors - FLASHES QUICKLY in case of errors that can be deactivated autoatically - ON in case of peranent errors 6 Single heating eleent slave reset button 7 Instruent panel 8 FOURTH heating eleent switch (only for Power Plus Box 00) 9 THIRD heating eleent switch 0 SECOND heating eleent switch FIRST heating eleent switch Main control panel Modular syste ain switch (only accessible by turning the ain control panel) 4 Electric power supply signal Modular syste block signal 6 Display 7 Value increase button 8 Value decrease button 9 Save button 0 Paraeter selection button Operating ode selection button Master reset button

17 Functional notes The Power Plus Box odular syste control panel anages: - The DHW priority function which, in the case of a DHW deand, the aster card can also serve the high or low teperature circuit. - The anti-freeze function, also active in stand-by ode, which starts the high teperature circuit circulator and the loop circulator if the anifold teperature drops below C. If there is an outdoor sensor, the circulators turn on if the outdoor teperature drops below C. If after 0 inutes the anifold teperature is less than C, a burner turns on at axiu power until the anifold teperature reaches 0 C. If after 0 inutes the anifold teperature exceeds C but the outdoor teperature is lower than C the circulators reain active until the outdoor teperature goes above that value. - The cascade anageent function: to anage the power delivered by the syste, it is possible to select between the iniu and axiu quantity of lit burners. - The exhaust function: the high and low teperature circuit pups reain in operation for inutes after the last burner is turned off. The waiting tie before the heating eleent circulator is stopped once the burner is shut off is 6 inutes. When the last burner is turned off, the circulator only stops when the roo therostat deand stops. - The ignition/shut-off control function: in both cascading anageent odes there is a burner ignition and shut-off liitation function in the case of low heat deand. - The syste anti-freeze protection function: the Power Plus Box condensing systes are equipped with freeze protection electronics. The electronics activate the heating unit if the teperature drops below the iniu threshold. Therefore the use of particular anti-freeze fluids are not necessary except in the case of uses with the equipent copletely shut off for long periods. If using anti-freeze fluids ake sure they are not aggressive for steel.. User interface (aster) The Power Plus Box syste control panel buttons have different functions depending on the ode. For exaple, a cobination of two buttons corresponds to a single function. Or a function is activated by pressing the button briefly or waiting approx. seconds. Reset Serves to release the electric board after a peranent arrest Set/esc Set: akes is possible to enter the paraeter change ode and onitor ode for the single units 7 This is used to view the operating status of the various circuits anaged by the Master card and Are used to increase or decrease a certain value OK Press to eorize new values

18 .. Display ode The red (error) LED turns on in the case of faults that involve the peranent block of a heating eleent (noral 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 digits with seven segents display the syste statuses: SYSTEM STATUS No deand for heating or hot water. The two right hand digits display flow teperature T. E.g. T = 0 C Deand for st syste or st and nd syste siultaneously. The two right hand digits display flow teperature T. E.g. T = 80 C Deand for hot water or siultaneous functioning. The two right hand digits display flow teperature T. E.g. T = 80 C The point after the first digit flashes. Deand for nd syste. The two right hand digits display flow teperature T. E.g. T = 80 C DISPLAY Antifreeze function.. Display ode Teperature 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. 8 POS. VISUALIZED VALUES DISPLAY Manifold delivery teperature T (e.g. T = 80 C) Hot water T (e.g. water tank tep. = 0 C) Outside teperature T4 (e.g. T4 = 7 C) 4 Flow teperature nd syste or low T6 syste 6 7 st syste roo therostat off or on (e.g. OFF = contact open; ON = contact closed) nd syste roo therostat off or on (e.g. OFF = contact open; ON = contact closed) 0-0V analogue input (e.g..v ; 0V respectively) 8 Mixer valve function status (e.g. closing, opening, pause) 9 0 Principal circulator function status. (e.g. circulator OFF; circulator ON respectively) Function status hot water syste circulator. (e.g. circulator OFF; circulator ON respectively) Second circulator function status (e.g. circulator OFF; circulator ON respectively) To exit the value display, press the "OK" button. If no operation is perfored within inutes, the card will autoatically return to display ode.

19 .. Changing the user paraeters Pressing displays the following values in succession: - anifold delivery teperature T - DHW teperature T - low teperature circuit delivery teperature T6. To change the relative setpoints: - press the "Set/esc" button: the relative value will appear, the two digits on the right will flash - if the value should not be changed, press Set/esc again to return to display ode - if the value should be changed, press and 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 ode For exaple s sake here below is a table showing the procedure for changing the setpoint value of the low tep. heating syste fro 0 to 40 C. POS. PROCEDURE DISPLAY E.g. value read on display for high syste 80 C Press button to enter display ode, press again and go to the first of 6 digits to visualize the set value (e.g. 0 C) Press button Set/esc 4 Press to take the setpoint to the desired value (e.g. 40 C) Press OK to eorize the new value 6 After secs. the display will return to the display ode with the new setpoint If there is no change after pressing Set/esc for 0 secs. (the desired value corresponding to the set one) the display returns to display ode function. If there is no operation after pressing buttons and, after one inute the display will return to display ode. The new selected value is not eorized...4 Monitor ode Press Set/esc for seconds to access "Monitor" ode. This ode is used to check the operating values for every syste unit (addresses fro to 60). POS. OPERATIONS DISPLAY 9 Fro current T position at 80 C Press Set/esc for secs. The displays shows it is possible to read the values or functional status of unit Press or to scroll and read the values of the desired unit (e.g. fig., unit 9) 4 Pressing the first value of the selected unit will appear. Afterwards by pressing the sae button the next values will be visualized. (e.g. fig., st value flow teperature NTC 70 C). Press Set/esc to exit onitor ode. The display will return to display ode function if it is not pressed within inutes or if no operation has been done.

20 The following values for each single unit can be visualized with : POS. DIMENSIONS DISPLAY Flow teperature (e.g. 70 C) Return teperature (e.g. 0 C) Exhaust flue teperature (e.g. 60 C) Ionization current (index fro 0 to 99). E.g. fig. Ionization current index 44. Fan PWM signal (%). If PWM = 00%, it corresponds to 99 on the display. E.g. fig. with 66%. Floweter contact open and closed (e.g. fig. contact open then contact closed) Circulator or otor-driven valve individual unit on/off. (e.g. fig. circulator on then circulator off) Maxiu ionization current (range fro 0 to 99) at first attept. E.g. fig. Maxiu ionization current value on display 80. Hours worked by unit (fro 0 to 9999 hours) E.g. fig. 800 hours: first thousands and hundreds then tens and units will appear in succession and coupled on the display 0.. Installer prograing ode The installer paraeters can be changed by entering the password (). The installer level password akes it possible to view and change the user and installer paraeters. Procedure for accessing the prograing ode: POS. PROCEDURE DISPLAY Manifold delivery teperature T (e.g. T = 80 C) Press Set/esc and OK. After s, the second and third digits will flash Use and to enter the second nuber of the password (the right digit). E.g: password = X 4 Press OK to save the second nuber of the password Use and to enter the first nuber of the password (the central digit). E.g: password = 6 Press OK to confir the password, if the password is incorrect, the card returns to the Display ode. If it is correct, the first paraeter P06 is displayed Press and to scroll the paraeters enabled by the password. 7 Press Set/esc to start to odify the paraeters. Now P-XX and the respective value will be shown alternatively on the display. Press and to change the paraeter value. 8 Each tie a button is pressed, the alternating display of the paraeter and the respective value stops for seconds and only the value is displayed. 9 Press OK to save the new paraeter value. To exit the installer prograing ode, press the Set/esc button. See the chapter "Paraeter list" for a coplete list of the paraeters.

21 ..6 Test ode In test ode it is possible to generate a high teperature heating deand at axiu power and at iniu power. All syste fans ust be activated. If the installer turns off the switch for soe Slaves, the others, connected to the Master, ust continue to operate. Proceed as follows to enter Test ode fro Display ode: POS. VISUALIZED VALUES DISPLAY Press Set/esc and at the sae tie for s. After s select the axiu speed or the iniu speed with the and buttons. All syste fans will operate at the selected speed. The first digit indicates the selected speed (H = axiu speed; L = iniu speed). The other two digits display the delivery teperature. E.g: T = 80 C. Press OK to exit Test ode and return to Display ode...7 Error ode The display starts to flash in case of a fault originating fro any heating eleent. Follow the procedure indicated for identifying the errors. POS. PROCEDURE DISPLAY The display starts to flash to indicate one or ore errors..b Press : 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. The errors of the subsequent units that are not functioning will be displayed in succession, pressing the button. By pressing the button, the errors will be displayed in reverse order (E.g. unit error code E0). If the errors originate fro the Master card, they are displayed as unit 00 errors (U 00 + error code). Press Set/esc to exit Error ode and return to Display ode. See the chapter "Fault list" for a coplete list of the errors...8 Peranent block In the case of burners with a peranent block, the Reset button ust be pressed to reset their operation. If the Reset button is pressed while in Display ode, all the Slave heating eleents will be reset. If the Reset button is pressed while displaying the error that caused the peranent block, only the heating eleent related to the block will be reset.

22 INSTALLATION. Unpacking the product The Power Plus Box condensing syste is supplied on a pallet, strapped and protected by cardboard packaging. Its condition and copliance with what was ordered ust be checked iediately. The specific characteristics of the product are indicated on the outside: odel, power, product code and serial nuber. If there is a discrepancy between what was ordered and what was received, iediately contact the local agent, warehouse or sales service.. Opening Reove the straps () and the cardboard packaging (). Strap Cardboard packaging Pallet 4 Modular condensing syste Docuent envelope containing: - Instruction anual - Hydraulic test and warranty certificate - Barcode labels 6 Accessory envelope containing: - Natural gas to LPG transforation kit (valid for Europe) - Door key The following is also supplied: positioned on the base inside the odular syste: - - DN - PN 6 flanges coplete with gaskets - - DN 80 - PN 6 flange coplete with gaskets - polypropylene coupling pipes for the flue gas anifold and condensate outlet positioned inside the control panel: - low teperature boiler/delivery sensor - outdoor sensor. b The docuent envelope () ust be kept in a safe place. Any copies ust be requested fro B, who will send the new docuentation within 4 days and who reserves the right to charge for the copies. a Do not dispose of packaging aterial into the environent, or leave it within the reach of children, since it can becoe a potential hazard. Dispose of packaging aterial in copliance with applicable legislation. 6 4

23 . Overall diensions and weights 660 SF 70 GAS GAS 0 MI MI 80 SC RI RI DESCRIPTION Power Plus Box 0 00 MI Syste delivery anifold " DN - PN 6 Ø - DN RI Syste return anifold " DN - PN 6 Ø - DN GAS Gas anifold " DN 80 - PN 6 Ø - DN SF Flue Manifold 60 Ø SC Condensate drain anifold 0 Ø Water drainage syste weight 0 40 Kg

24 .4 Handling A transpallet or forklift ust be used for handling. A transpallet or forklift ust be used for handling. b The packaging aterial ust be disposed of carefully and ust not be abandoned, as it is a source of potential danger.. Installation preises The Power Plus Box systes (odels EXT) are designed for outdoor installation. In the case of installation indoors (odels INT), they are B category devices and ust be installed in peranently ventilated roos in copliance with the currently applicable Technical Regulation. In this case, a suitable syste ust be prepared for collecting condensate and for flue gas exhaust (see the specific chapter "Flue gas evacuation for installations in central heating plants ). b Take into consideration the space that is required in order to access the safety and control devices and to perfor the aintenance operations. If possible, aintain a distance of approx. etre between the rear panel and the wall. Note that the front doors can be reoved easily. b Check that the appliance's electrical protection level is suitable for the place of installation. 4 0 A transpallet or forklift ust be used for handling. - place two wooden boards () near the pallet () - slide the odular syste above the wooden boards - adjust the feet () of the odular syste until they rest on the ground - slide the wooden boards out Installation in older systes and systes requiring odernisation If the syste is being installed in an old or refurbished syste, check that: - If installing in a central heating plant, the flue is suitable for the condensing equipent, at the teperatures of the products of cobustion, calculated and built according to standard. it is as straight as possible, air-tight, isolated and not have obstructions or constrictions - Make sure that the flue is fitted with a condensation drainage union

25 - Make sure that the electrical supply syste has been installed by a qualified electrician in copliance with applicable standards - Make sure that the flow rate, head and direction of flow of the pups are suitable and correct - Make sure that the fuel feed line and any storage tank are ade and installed in copliance with applicable standards - Make sure that expansion vessels are big enough to contain the additional volue generated by theral expansion - The syste has been cleaned of sludge and deposits..7 Water connections The Power Plus Box condensing systes are designed and built to be installed in hot water heating systes. 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 anifolds and of the flue gas anifold in the case of an installation in a central heating plant. Also take the electrical connections (0V~0Hz power supply) of the condensing odules into account. Position the odular syste(s) and the technical cabinet with the hydraulic separator near the syste's delivery and return anifolds. To ake it easier to position the odular syste in the area of installation, refer to the "Handling" paragraph. Adjust the feet of the cabinet if necessary to level the, aking it possible to easily open and close the doors and align the anifold flanges. Counterflanges and blind flanges for the water and gas anifolds can be purchased easily on the arket. b Provide the syste filling, draining and safety coponents, expansion tank, etc. b The use of a hydraulic copensator is andatory. POWER PLUS BOX COMPENSATORE IDRAULICO Power Plus Box odular syste Hydraulic copensator Gas supply 4 Autoatic vent valve Maxiu pressure switch connection 6 Control theroeter connection 7 Gas shut-off sensor trap 8 Bietallic theroeter connection 9 6 bar pressure gauge connection 0 Collector teperature sensor socket Expansion tank connection Return theroeter connection Safety valve connection 4 Theroeter connection Drain cock 6 Flanged pipe 7 Manifold delivery sensor trap 8 Disconnect valves 9 Syste pups 0 Non-return valves Outlet connection Flue gas exhaust anifold connection Drain

26 .8 Flue gas evacuation for installations in a central heating plant When constructing evacuation lines for installations in a central heating plant, aterials ust be used that are resistant to products of cobustion (teperature between 40 C and 00 C, relative huidity also above 00%), in class W according to UNI EN 44, typically stainless steel or plastic aterials. It is also necessary to guarantee the tightness of the entire evacuation line with regard to the pereability of condensed stea and gas pursuant to the current regulation (UNI EN 44). The connection sections between the chiney and the boiler ust have a iniu slope of towards the boiler so that any condensate that fors in this line section can be evacuated using a suitable exhaust device. The Power Plus Box odular condensing systes have been approved coplete with a flue gas evacuation line in self-extinguishing PP or suitable aterials based on EN 677 and correlated standards. The flue gas exhaust syste foresees the use of pipes with the diaeters indicated in the table. All of the indicated diaeters refer to lines in self-extinguishing polypropylene (class B), ipleented with pipes with socketed connections or equivalent lines. The axiu equivalent length of the flue gas evacuation lines is indicated in the table. Each odular syste is provided with feale socketed connections Ø 60 for the exhaust of cobustion products to the right and to the left. Description Maxiu useful output (kw) Maxiu equivalent length () Flue gas evacuation line diaeter () Power Plus Box Power Plus Box (Power Plus Box 0) x (Power Plus Box 00) x Equivalent length for the various line eleents () Type of eleent with Ø 60 with Ø 00 4 bend,7,7 87 bend 7, 7, T-union 7, 7, b The flue ust be sized according to the current standard UNI 79 and be as straight as possible without obstructions or constrictions. b A stea trap is andatory for flue gas lines longer than etres. b Make sure that there is a iniu slope of in the horizontal sections of the flue gas anifold to avoid the accuulation of condensation. b In the event of installation with air intake fro the preises (both in the heating unit and externally) avoid obstructing the passage of air under the etal cupboard.

27 .9 Condensate evacuation Power Plus Box condensation systes produce a condensate flow depending on the operating conditions. The axiu hourly flow of condensation produced is indicated for every odel in the technical data table. The condensate outlet syste ust be sized for that value and the cross section ay not be saller in any section than the diension of the connection to the condensate outlet anifold (SC). The condensate outlet anifold is supplied already installed. Therefore it is only necessary to connect the outlet (SC) coing fro the odular syste to the drainage syste. b Always keep the inclination angle i greater than % and the diaeter of the condensate outlet pipe always greater than the union on the odular syste. b Any condensate neutralisation devices can be connected after the siphon. For the calculation of the duration of the neutralisation load, the aount of neutraliser consuption ust be evaluated after one year of operation. The total duration of the load can be extrapolated fro this inforation. b Pay particular attention to fixing the condensate evacuation pipe fro the siphon located on the flue gas exhaust anifold and fro the condensate outlet anifold. i i % SC SC b The connection to the drainage syste ust be ade according to current laws in copliance with any local regulations. b Fill the water pipes () for connecting to the condensate outlet anifold in order to avoid products of cobustion fro entering the environent during the first inutes of odular syste ignition. b If installing in a central heating plant, it is recoended to direct both the products deriving fro the boiler condensate outlet as well as the condensate deriving fro the flue gas anifold to the sae exhaust outlet. b The boiler base ust be horizontal and flat in the area of the support frae to prevent probles with condensate evacuation. i > Scarico Civile.0 Neutralising the condensate The N and HN neutralisation kits are available for condensate neutralisation. N TYPE NEUTRALISATION KIT The N TYPE neutralisation units were designed for systes 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 Diensions L - Width 400 H - Height 0 P - Depth 00 7

28 A P C HN TYPE NEUTRALISATION KIT The HN TYPE neutralisation units were designed for systes equipped with the central heating plant condensate outlet trap located higher than the boiler condensate outlet. This neutralisation kits does require electric connections. Description Diensions L - Width 400 H - Height 0 P - Depth 00 Q.ty of granulate kg L B H Maintenance Neutralisation device aintenance ust be perfored at regular intervals and as required (iniu once per year). The requireent for aintenance depends on the syste characteristics. For this purpose, the filling level of the doloitic granules ust be checked. The iniu filling level is equal to c, starting fro the upper edge of the box. The first filling of neutralisation product is sufficient at least for one heating season in the case of axiu forulation of condensate. The operation can be checked easily using the ph indicator cards available coercially. They can be purchased fro any pharacy or store selling cheical products. The condensate that exits ust have a ph value between 6. and 9. If any deposits are found on the surface of the neutralisation device during aintenance, it is recoended to replace the granulate.. Electrical connections Power Plus Box systes leave the factory copletely wired and the only connections required are the electric power supply cable, the roo therostats, the outdoor sensor and the user circulators, using the dedicated terinals. Proceed as follows: - switch the boiler OFF at the ains power switch 8, ax - open the two front doors in the casing - loosen the screw () and turn the ain control panel () - loosen the screws (), turn the instruent panel (4). Insider, there is the low teperature delivery/boiler sensor and the outdoor sensor (to be connected). B H P A L C

29 6 4 J0 J9 J8 Pup Pup Pup 0 Valv.Mix OFF ON Alar V Co. Bus Analogic Input Circ. r NTC NTC NTC Circ. NTC 4 ROTATE ROTATE identify the cable glands () located on the rear part of the odular syste and use the to pass the pup, sensor and electric power supply cables inside the odular syste - Identify the terinal board (6), located inside the electric panel, and direct the pup and sensor cables (7) towards it through the holes ade in the panel casing. Make the connections as shown in the diagra on the following page, referring to the wiring diagras. - Provide a three-pole cable (8) to supply the 0V~0Hz line, direct it through the hole ade in the casing of the electric panel and connect it to the switch (9) as indicated on the wiring diagras b If coupling ultiple odular systes with a cascade connection, a power supply cable ust be provided for each odular syste.

30 TERMINAL BOARD INSIDE THE CONTROL PANEL Pup 8 7 PB (*) DHW circulator SZ High teperature zone sensor NTC Pup 6 PZ (*) Syste circulator High teperature SB Boiler sensor 4 NTC Pup Valv. Mix 0 OFF ON Alar PZ (*) VM (*) Mixer valve Alar signalling contact Syste circulator Low teperature CR Reote control TA "Roo therostat Low teperature" IA Analogue input 0-0V SZ Low teperature zone sensor SE External sensor TA Roo therostat High teperature NTC Circ. NTC V Co BUS "Analogue Input" Circ. 0 (*) 0V~0Hz b The following is andatory: - The use of an onipolar agnetotheric switch, line disconnecting switch in copliance with CEI- EN standards (contact opening of at least ) - Respect the connection L (line) - N (neutral). Keep the earth conductor c longer than the power supply conductors - Use cables with a section greater than or equal to., coplete with cable terinal caps - Refer to the wiring diagras in this anual for all electric operations - Connect the equipent to an effective earthing syste. b The circulators ust be connected with the interposition of suitable contactors with anual eergency actuation. a It is strictly forbidden to use pipes of any kind to ground the appliance. a It is prohibited to pass the power supply and roo therostat cables near hot surfaces (delivery pipes). If contact is possible with parts that have teperatures above 0 C, use a suitable type of cable. The anufacturer is not responsible for any daage caused by failure to earth connect the device and failure to coply with what is indicated in the wiring diagras. NOTE: for sensor positioning, see the "Sensor positioning" chapter.