NOVELLA RAI BOILERS CAST IRON BASE INSTALLATION MANUAL

NOVELLA 55-64-71 RAI BOILERS CAST IRON BASE INSTALLATION MANUAL

2INSTALLATION MANUAL Novella boilers conform to the basic requirements of the following directives: Gas Appliances Directive 2009/142/CE Boiler Efficiency Directive 92/42/CEE ( ) Electromagnetic Compatibility Directive 2004/108/CE Low Voltage Directive 2006/95/CE Novella boilers are therefore CE marked. 0694 The following symbols are used in this manual: b CAUTION! = Indicates actions that require caution and adequate preparation a STOP! = Identifies actions that you MUST NOT do

CONTENTS 1 SAFETY INFORMATION AND PRECAUTIONS...4 2 DESCRIPTION OF THE APPLIANCE... 5 2.1 Description...5 2.2 Optional accessories...5 2.3 Main parts of the boiler...6 2.4 Control panel...6 2.5 Technical specifications...7 2.6 Identification...8 2.7 Material supplied...8 2.8 Handling...9 2.9 Overall dimensions and water fittings...10 2.10 Water circuit...10 2.11 Wiring diagram...12 3 INSTALLATION... 13 3.1 Installation standards...13 3.2 Place of installation...13 3.3 Installation in existing systems...13 3.4 Water connections...14 3.5 Electrical connections...14 3.6 Gas connections...16 3.7 Gas supply conversion...16 3.8 Flue gas vent and air intake...18 3.9 Filling the water circuit...19 3.10 Emptying the water circuit...19 4 START-UP AND FUNCTIONING... 20 4.1 Preliminary checks...20 4.2 Ignition...20 4.3 Final checks...22 3 5 SHUT-DOWN... 23 6 MAINTENANCE... 24 6.1 Scheduled maintenance...24 6.2 Extraordinary maintenance...24 7 OPTIONAL ACCESSORIES... 25 8 NOVELLA BOILERS: MODULAR CONFIGURATION... 26 8.1 Configurations...26 8.2 Overall dimensions...27

4INSTALLATION MANUAL 1 SAFETY INFORMATION AND PRECAUTIONS bbthis manual and the operation manual associated with it form integral parts of the product. Make sure that they are always kept with the boiler even if it is transferred to another owner or user, or re-installed elsewhere. If you damage or lose this manual, order a replacement immediately from your local Technical Assistance Service. bbthe boiler must only be installed and serviced by qualified personnel, in conformity to applicable legislation (in Italy, law 46 of the 05/03/1990) and applicable technical standards (in Italy, UNI- CIG 7129 and 7131 standards and subsequent updates thereto). bbthe boiler must only be used for the purpose for which it is designed. The manufacturer declines all responsibility, contractual or other, for damage to property or injury to persons or animals caused by improper installation, adjustment, maintenance or use. bbas soon as you open the packaging, check immediately that the contents are all present and undamaged. Contact the reseller from whom you purchased the product if you notice any problems. bbthe safety valve must be connected to a suitable collection and drain system. The manufacturer declines all responsibility for damage caused by the operation of an improperly connected safety valve. bbthe following instructions must be passed on to the user on installation of the boiler. - If water leaks from the boiler, turn off the water supply and contact the manufacturer s Technical Assistance Service immediately. - Periodically check that operating pressure in the water circuit is over 1 bar. If necessary, contact the manufacturer s Technical Assistance Service to arrange servicing by professionally qualified personnel. - If the boiler is not going to be used for an extended period of time, contact the manufacturer s Technical Assistance Service to have at least the following operations performed: Switch the boiler OFF at the control panel and at the mains power switch Close the boiler s fuel cock, central heating circuit shut-off cock and domestic hot water circuit shut-off cock Empty the central heating circuit and domestic hot water circuit if there is any risk of freezing - The boiler must be serviced at least once a year. Servicing must be arranged in advance with the manufacturer s Technical Assistance Service Observe the following precautions to ensure safe operation of the boiler. aado not allow children or uninformed persons to operate the boiler. aado not operate any electrical devices or equipment, including switches or domestic appliances, etc., if you can smell fuel or fumes. In the event of a gas leak, thoroughly ventilate the room by opening wide all doors and windows, close the gas shut-off valve and call the manufacturer s Technical Assistance Service immediately to arrange urgent assistance by professionally qualified personnel. aado not touch the boiler while barefoot or wet. aanever clean the boiler without first disconnecting it from the mains electricity supply by turning the mains power switch and the control panel switch OFF. aado not tamper with or adjust the boiler s safety or control devices without prior authorisation and instructions from the manufacturer. aado not pull, disconnect, or twist the electrical cables coming from the boiler even if it is disconnected from the mains electricity supply. aado not obstruct or restrict vents in the room where the boiler is installed. Adequate ventilation is essential for correct combustion. aado not store containers of flammable substances in the room where the boiler is installed. aado not leave items of packaging within the reach of children.

2 DESCRIPTION OF THE APPLIANCE 2.1 Description Novella RAI boilers are gas fuelled boilers for domestic heating. They are equipped with an atmospheric burner and a cast iron primary heat exchanger. They incorporate an open (type B11BS) combustion chamber and are fitted with a hood that ensures proper flue gas venting even with a fluctuating flue draught. They are also equipped with a flue gas thermostat, as required by applicable safety standards. The burner is a stainless steel unit with stabilised flame and smooth ignition. The burner is fitted with an ionisation type flame detection system. The boiler s control and safety devices conform to applicable technical and safety standards and are enclosed in a functional control panel integrated in the body of the appliance Novella boilers use total shut-down logic and do not waste energy because they only start up when heat is actually needed by the central heating system (i.e. when the room thermostat trips). Novella boilers can be connected to a storage cylinder to produce domestic hot water, and can be equipped with temperature controllers in the form of specific accessories. Installation, maintenance and access to internal components is facilitated by a large front panel. The key features of these boilers include: electronic ignition with ionisation flame detection adjustable smooth ignition gas supply solenoid valve with built-in pressure stabiliser and double shutter for burner control domestic hot water temperature control water circuit temperature and pressure gauge provision for room thermostat or timer. 2.2 Optional accessories Wall-mounted weekly timer thermostat (part number 1100279) High head pump kit (part number 1100269) RO120 storage cylinder (part number 696339) Pump or valve controlled multizone central heating kit with total shut-down function (part number 696439). 5

6INSTALLATION MANUAL 2.3 Main parts of the boiler Key 1 Control panel 2 Temperature sensor socket 3 Gas pressure switch (minimum pressure) 4 Electronic ignition and flame detection unit 5 Gas supply solenoid valve 6 Ignition electrode 7 Water circuit drain cock 8 Flame detection sensor 9 Burner 10 Boiler body 11 Name plate 11 10 9 8 7 1 2 3 4 5 6 Fig. 2.1 2.4 Control panel Key 12 Main switch 13 Central heating temperature control 14 Central heating temperature gauge 15 Safety thermostat (manual reset) 16 Flue gas thermostat (manual reset) 17 Burner lockout LED warning light 18 Power on LED indicator 19 Quick reference guide 20 Burner reset button 12 13 14 15 16 20 19 18 17 19 Fig. 2.2

2.5 Technical specifications 55 RAI 64 RAI 71 RAI Rated heat input, CH kw 61,0 70,5 79,0 kcal/h 52460 60630 67940 Rated heat output, CH kw 55,0 63,5 71,1 kcal/h 47300 54600 61150 Electrical consumption W 23 Boiler class II 2H3+ Power supply voltage V ~ Hz 230 ~ 50 Index of protection IP 40 Losses from stack and casing with burner off % 1,12 1,26 1,05 Central heating circuit characteristics Maximum pressure - temperature bar - C 3-100 CH temperature setting range C 34-82 Gas pressure Rated gas pressure, methane (G 20) mbar 20 Rated gas pressure, LPG (G31) (G 30 - G 31) mbar 28-30/37 Water connections CH flow - return Ø 1" 1/4 Gas inlet Ø 1/2" 3/4" Emissions with G 20 gas CO below p.p.m. 34 31 52 CO2 % 4,90 5,75 5,70 NOx (according to EN 297) Class 1 Flue gas Δt C 113 123 130 Boiler dimensions Height mm 850 Width mm 450 Depth mm 712 795 878 Weight of boiler kg 190 225 251 7 PARAMETER 55 RAI 64 RAI 71 RAI Lower Wobbe index (at 15 C-1013 mbar) G20 (MJ/m 3 ) 45,7 (at 15 C-1013 mbar) G30 (MJ/m 3 ) 80,9 (at 15 C-1013 mbar) G31 (MJ/m 3 ) 71,0 Rated supply pressure G20 mbar (mm H 2 O) 20 (203,9) G30 mbar (mm H 2 O) 28 (285,5) G31 mbar (mm H 2 O) 37 (377,3) Minimum supply pressure G20 mbar (mm H 2 O) 13,5 (137,7) G30 mbar (mm H 2 O) - G31 mbar (mm H 2 O) - Main burner 2 nozzles G20 Ø mm 4,60 5,00 5,40 G30 Ø mm 2,60 2,85 3,00 G31 Ø mm 2,60 2,85 3,00 Maximum pressure downstream from valve in central G20 mbar Δp 12,5 12,8 12,5 heating only mode mm H 2 O Δp 127 130 127 G30 mbar Δp 25,5 25,5 24,5 mm H 2 O Δp 260 260 250 G31 mbar Δp 34,0 34,5 34,0 mm H 2 O Δp 346 351 346 Maximum gas flow rate, CH (*) G20 m 3 /h 6,40 7,40 8,29 G30 kg/h 4,50 5,50 6,20 G31 kg/h 4,50 5,50 6,20 (*) Temperature 15 C; Pressure 1013 mbar

8INSTALLATION MANUAL 2.6 Identification Novella boilers are identified by a product name plate giving the boiler s serial number, model and main technical and performance data. bbit is essential to specify the correct model of boiler when ordering spare parts or requesting technical assistance. If the name plate or any other means of clearly identifying the product is defaced, removed or lost, proper installation and servicing may be rendered difficult. 2.7 Material supplied GAS FUELLED BOILER Model Serial No. Code PIN Code Year Heat input at Boiler water furnace (Qn/Hi) capacity Useful heat Heat exchanger output (Pn) surface area Maximum working Maximum admissible pressure (mwp) temperature Maximum current Power supply draw Maximum energy NOx class consumption Gas supply pressure Index of protection OBLIGATORY GROUND CONNECTION CLASS OF BOILER TYPE OF BOILER COUNTRY OF DESTINATION Fig. 2.3 The boiler is delivered in a wooden cage. Proceed as follows to remove this. Remove the staples fixing the wooden cage to the pallet. Lift off the wooden cage. The following items are delivered in a plastic bag inside the boiler: Operation manual Installation manual LPG conversion kit (nozzles, label, seals) 2 lifting plates. Instruction manuals are integral parts of the boiler. On unpacking, locate the manuals and keep them safe. Fig. 2.4 Novella boilers come with a back draught shutter in a separate box. MODEL 55 RAI 64 RAI 71 RAI Net weight 190 225 251 kg Gross weight 207 243 271 kg

2.8 Handling C B P Fig. 2.5 Once you have removed the packaging, proceed as follows to handle the boiler: Remove the screws securing the boiler to the wooden pallet. Remove the front panel (P) and top panel (C) from the casing (fig. 2.5). Unscrew the nut (A) from the top front tierod (fig. 2.6). Fit one of the lifting plates (B) over the end of the tie-rod (C) (fig. 2.6). Screw the nut (A) back on (fig. 2.6). Unscrew the nut (D) from the top rear tie-rod (fig. 2.7). Fit the second lifting plate (E) over the end of the tie-rod (F). Make sure that the second lifting plate is diagonally opposite that fitted previously (fig. 2.7). Screw the nut (D) back on (fig. 2.7). Lift the boiler using a 1" pipe (G) inserted through the two lifting plates (fig. 2.8). Once the boiler is in its final installation position, reverse the above steps to remove the two lifting plates. Securely tighten the nuts. E A C Fig. 2.6 bbwear suitable personal protective equipment and use suitable safety devices. aado not leave items of packaging within the reach of children. 9 D F Fig. 2.7 G Fig. 2.8

INSTALLATION MANUAL 10 2.9 Overall dimensions and water fittings DESCRIPTION MODEL 55 RAI 64 RAI 71 RAI A 712 795 878 mm B 260 302 342 mm C 1475 1475 1700 mm Fig. 2.9 2.10 Water circuit GAS MI A Water circuit drain cock B Water circuit temperature control sensor C Safety thermostat temperature sensor D Water circuit temperature gauge sensor MI CH flow RI CH return GAS Gas supply RI A B C D Fig. 2.10

Boiler s water-side pressure drop Novella RAI boilers come without a pump. A pump must therefore be provided as part of the installation. In order to choose a pump of the right size, bear in mind the boiler s water-side pressure drop, as shown in the following graph. 0,04 Pressure drop (m approx.) 0,035 0,03 0,025 0,02 0,015 0,01 0,005 Novella 55 RAI Novella 64 RAI Novella 71 RAI 0 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 Flow rate (l/h) Fig. 2.11 Fig. 2.12 bbon initial start-up and at least every year, check that all the pumps in the system rotate freely. Sludge and limescale can build up and cause seizure, especially after long periods of disuse. aanever run the pump dry. 11

INSTALLATION MANUAL 2.11 Wiring diagram 12 RS Burner reset button EA Ignition electrode TR Central heating temperature control ER Flame detection sensor TS Safety thermostat (manual reset) P1 Gas pressure switch IG Main switch TF Flue gas thermostat (manual reset) FU Fuse PI CH pump LV Green power on LED indicator AP Ignition and flame detection unit LR Red burner lockout LED warning light VG Gas supply solenoid valve Fig. 2.13

3 INSTALLATION 3.1 Installation standards L'installazione dev'essere eseguita da personale qualificato in conformità alle seguenti normative di riferimento: UNI-CIG 7129 UNI-CIG 7131 CEI 64-8. Installers must also ensure conformity to fire prevention standards, gas safety standards and local bylaws. 3.2 Place of installation Novella RAI boilers must be installed in boiler rooms with vents that conform to applicable technical standards and safety legislation. aaboilers must be installed indoors. They are not designed for outdoor use and are not fitted with automatic frost protection devices. IMPORTANT Before installing the boiler, thoroughly flush out all pipes to remove any dirt and deposits that could compromise the correct functioning of the boiler. Install a water collector under the safety valve and connect it to the nearest drain to evacuate any water coming out of the safety in the event of overpressure. The domestic hot water circuit does not require a safety valve but the installer should nevertheless check that the water supply pressure does not exceed 6 bar. If necessary, install a pressure reducer. Before lighting the burner for the first time, make sure that the boiler is configured for use with the type of gas supplied. The type of gas is specified on the packaging label and on the boiler s own name plate. Make sure that the flue is able to withstand the temperature of the flue gases and that it has been designed and made in conformity to applicable standards. The flue must also be as straight as possible, sealed, insulated and not blocked or choked. 3.3 Installation in existing systems Perform the following checks before installing Novella RAI boilers in existing systems. Check that the flue is large enough and suitable for the characteristics of the boiler. Check that the characteristics of any existing central heating pump are suitable for the boiler (see the graph on page 11). Make sure that the central heating circuit has been flushed out to remove all sludge and limescale, and that it has been properly de-aerated. Make sure that the system is fitted with safety and control devices that conform to applicable legislation and standards. Check the hardness of the water supply to ascertain whether a softening system is required. Refer to the following values. REFERENCE VALUES ph 6-8 Electrical conductivity less than 200 mv/cm (25 C) Chlorine ions less than 50 ppm Sulphuric acid ions less than 50 ppm Total iron less than 0,3 ppm Alkalinity M less than 50 ppm Total hardness 35 F Sulphur ions none Ammonia ions none Silicon ions less than 30 ppm 13

INSTALLATION MANUAL 14 3.4 Water connections Novella boilers are designed and made for use in central heating systems, but can also be used to generate domestic hot water if connected to a suitable storage cylinder. The specifications of the water fittings are as follows: MI CH outlet Ø 1 1/4 F RI CH return Ø 1 1/4 F bbthe RO120 storage cylinder water connections kit (part number 596369) adapts the boiler s water connections to a different diameter: MI CH flow Ø 3/4 F RI CH return Ø 3/4 M bbthe choice of system components and the method of their installation are left up to the heating engineer installing the system. Installers must use their expertise to ensure proper installation and functioning in conformity to all applicable legislation. bbcircuits filled with anti-freeze must be fitted with water disconnectorsrici. MI RI Fig. 3.1 3.5 Electrical connections Il collegamento alla rete elettrica deve essere realizzato tramite un dispositivo di separazione con apertura onnipolare di almeno 3 mm. L'apparecchio funziona con corrente alternata a 230 V~50 Hz, ha una potenza elettrica di 150 W ed è conforme alla norma EN 60335-1. - Always refer to the electrical wiring diagrams in this manual when performing any electrical work. - Ensure that an efficient ground connection is provided. bbthe following instructions are mandatory: - Install a multi-pole magnetic thermal trip switch and disconnector conforming to IEC-EN standards (with a contact gap of at least 3 mm). - Respect the polarity of the L1 (Phase) - N (Neutral) connections. - Use cables with insulation and cross section conforming to applicable standards (minimum cross section 1.5 mm2). a a It is strictly forbidden to use fuel and/ or water pipes to ground the appliance. The manufacturer declines all responsibility for damage caused by failing to ground the appliance adequately.

Unscrew the two fixing screws and remove the protective cover (A) from the casing (fig. 3.2). The electrical connection terminals are located underneath (fig. 3.3). Connect up the (optional) room thermostat and/or timer as shown in the electrical wiring diagrams in this manual. Fig. 3.2 Connect up the electrical power supply (fig. 3.3) 15 Fig. 3.3 Connect up the room thermostat (TA) (fig. 3.4). bbif a room thermostat is connected, remove the bridge from terminals 4-5. bbthe contacts of the room thermostat must be able to function at a voltage of 230 V, 50 Hz. Fig. 3.4

INSTALLATION MANUAL 3.6 Gas connections Novella boilers must be connected to the methane or LPG gas supply in conformity to applicable standards (fig. 3.5). Perform the following checks before making the connection. Check that the boiler is compatible with the type of gas supply. Check that the gas supply pipes are thoroughly clean. Fit a suitably sized filter in the gas supply pipe if the gas supply contains any solid particles. bbthe gas supply line must be suitable for the flow rate demanded by the burner. The gas supply must also be equipped with all the necessary safety and control devices required by applicable legislation and standards. bbon completion of the installation, check that all joints are sealed in conformity to the relevant installation standards. GAS GAS - Gas supply Fig. 3.5 16 3.7 Gas supply conversion The boiler comes ready for use with methane gas (G20), but can be converted to work with LPG (G30/G31) using the conversion kit provided and the LPG gas valve contained in the relevant kit (part number 1102259). Conversion must be performed by the manufacturer s Technical Assistance Service. The boiler can be converted even after installation. To do so, proceed as follows. Fig. 3.6 REPLACING THE NOZZLES Remove the front panel from the casing. Unscrew the two nozzles from the methane burner and replace them with the LPG nozzles, using the aluminium seals provided in the kit (fig. 3.6). DISABLING THE PRESSURE REGULATOR For the boiler to work with LPG fuel, the pressure regulator on the valve group needs to be disabled. To do so, proceed as follows: Remove the plug (1). Screw the pressure regulator screw (2) all the way in (fig. 3.7). Unscrew the pressure measurement point screw (A) about 3 turns and connect up the pressure gauge (fig. 3.7). Instead of the plug (1), fit the blind plug provided in the conversion kit (fig. 3.7). A 2 1 Fig. 3.7

B ADJUSTING THE GAS PRESSURE SWITCH Unscrew the screws (B) securing the pressure switch cover (fig. 3.8). Fig. 3.8 Adjust the pressure switch knob (C) to 20 mbar (fig. 3.9). Fit the cover back on and secure it with the screws removed previously. C Fig. 3.9 Start up the boiler as instructed on page 20. NOZZLE PRESSURE Adjust the pressure regulator on the LPG supply until the pressure gauge reads out the value specified in the table below (fig. 3.11): 55 RAI 64 RAI 71 RAI G30 G31 G30 G31 G30 G31 25,5 34,0 25,5 34,5 24,5 34,0 mbar 17 Fig. 3.10 Disconnect the pressure gauge and close the pressure measurement point. Check the tightness of all the joints disconnected previously. Apply the LPG label supplied with the boiler to the inside of the boiler casing (fig. 3.11). Remove any METHANE (G20) labels from the outside and inside of the boiler casing (fig. 3.11). Country of destination: Boiler configured for: G30+G32 28-30/37 mbar L.P.G. Country of destination:... Fig. 3.11

INSTALLATION MANUAL 3.8 Flue gas vent and air intake Flues and stack connections must be made in conformity to all applicable local and national laws and standards. The use of rigid pipes is mandatory. All joints between pipe sections must be hermetically sealed and all parts of the flue must be resistant to high temperatures, condensate and mechanical stress. bbnovella boilers are equipped with a flue gas thermostat, located inside the hood. This thermostat shuts down the boiler immediately in the event of flue gas blowback. bbuninsulated flue pipes are potentially dangerous and can cause burns. DESCRIPTION A Øi MODEL 225 225 55 RAI 64 RAI 71 RAI Fig. 3.12 A 260 302 342 mm Ø I 182 182 202 mm 18 The back draught shutter supplied with Novella boilers must be fitted correctly along with the flue gas thermostat. To do so, proceed as follows. Fit the collar (C) to the flue gas exhaust hole in the top panel of the casing (fig. 3.13) B C Push the back draught shutter (B) through the collar (C) and into its seat in the flue gas hood (fig. 3.13) Fig. 3.13 Insert the flue gas thermostat (S) (attached to the back of the boiler), into the socket in the back draught shutter and fix it in place with the nut (fig. 3.14). S Fig. 3.14

3.9 Filling the water circuit RI Novella series boilers must be fitted with a water circuit filling system connected to the boiler return line (fig. 3.15). Fig. 3.15 Make sure that the boiler drain cock is closed before attempting to fill the boiler (fig. 3.16) Fig. 3.16 RI Fig. 3.17 Open the water circuit shut-off cocks and slowly fill the circuit until the pressure gauge reads out a value of 1.5 bar (cold). Close the water circuit shut-off cocks (fig. 3.17). 19 3.10 Emptying the water circuit ON OFF Fig. 3.18 Turn the electricity supply off by switching the boiler s mains power switch and control panel switch OFF (0) before starting to empty the boiler (fig. 3.18). Make sure that the water circuit shut-off cocks are closed. - - Connect a rubber hose to the hose union on the boiler s drain cock and open the cock (fig. 3.19). Fig. 3.19

INSTALLATION MANUAL 4 START-UP AND FUNCTIONING 4.1 Preliminary checks Remove the front panel of the boiler and perform the following checks before switching the boiler on or testing any of its functions. Check that the fuel and water circuit shut-off cocks are open Check that the type and pressure of the gas supply are as specified for the boiler. 4.2 Ignition Check that the water circuit pressure gauge shows a pressure over 1 bar with the system cold. Check also that the central heating circuit is properly de-aerated. Check that the pressure in the central heating circuit expansion vessel is sufficient (about 1 bar). Check that the electrical connections to the mains supply and to the system s control and safety devices have been made correctly. Check that the flue is properly constructed. Once you have completed all the preparatory steps, proceed as follows to start up the boiler for the first time. 20 - - Turn the boiler s mains power switch ON Fig. 4.1 (fig. 4.1) Set the room thermostat to the required temperature (~ 20 C) or, if the system has a timer or timer-thermostat, make sure that this is switched On and adjusted to the required temperature (~ 20 C) (fig. 4.2) Fig. 4.2 Adjust the boiler s temperature control to the desired temperature (operation not necessary if the boiler has been equipped with a temperature controller) (fig. 4.3) Fig. 4.3 Switch the boiler on at the control panel switch and check that the green power indicator lights (fig. 4.4). Fig. 4.4

The boiler will now start up and the burner will remain lit until the set temperature is reached. If any ignition or functioning errors occur, the boiler enters LOCK-OUT and the red LED on the control panel comes on to indicate this (fig. 4.5). Fig. 4.5 Proceed as follows to reset the safety thermostat. Wait for about 1 minute, then press the "burner reset" button (fig. 4.6). Wait for the burner to complete the entire start-up cycle again, up to the ignition of the flame. Fig. 4.6 The boiler will also shut down if the flue gas thermostat trips. To reset the boiler in this case, remove the hood and reset the flue gas thermostat (fig. 4.7). Fig. 4.7 bbif the flue gas thermostat trips repeatedly, make sure that the flue gas pipes are not blocked and that the flue is properly constructed. bbnovella boilers are equipped with a factory-calibrated minimum pressure switch for the gas supply. This shuts down the boiler if the gas supply pressure is not sufficient to ensure correct functioning. Operation of this pressure switch is not signalled. 21

INSTALLATION MANUAL 4.3 Final checks Once the boiler has started up, make sure that it shuts down and re-starts properly when the following actions are taken. The boiler s temperature control is turned down (fig. 4.8). The control panel switch is switched OFF (fig. 4.8). The temperature setting on the room thermostat or timer is reduced (fig. 4.9). Make sure that the pump (if fitted) is free and rotates in the right direction (fig. 4.10). Turn the mains power switch OFF and make sure that the boiler shuts down completely (fig. 4.11). Fig. 4.8 Fig. 4.9 Provided these conditions are satisfied, restart the boiler. 22 Fig. 4.10 ON OFF Fig. 4.11

5 SHUT-DOWN If the boiler is not going to be used for an extended period of time, perform the following operations. Fig. 5.1 Switch the boiler on at the control panel switch and check that the green power indicator lights (fig. 5.1). ON Turn the mains power switch OFF (fig. 5.2). OFF Fig. 5.2 Close the boiler s fuel cock and water circuit cock (fig. 5.3). Fig. 5.3 bbempty the boiler if there is any risk of freezing 23

INSTALLATION MANUAL 6 MAINTENANCE To maintain maximum functionality and efficiency, and to comply with applicable legislation, have the boiler serviced at regular intervals. The frequency at which servicing should be performed depends on installation and operating conditions. The boiler should nevertheless be inspected by specialist personnel from the manufacturer s Technical Assistance Service at least once a year. Always switch the boiler off if any work or servicing has to be done on other equipment installed near the flue gas vent pipes and/or flues and associated accessories. On completion of work, have the efficiency of the flue checked by qualified personnel. bbswitch the boiler off at its control panel and at the mains power switch, and turn the gas supply off by closing the gas shut-off cock before performing any cleaning or maintenance on the boiler. 6.1 Scheduled maintenance Do not use flammable substances (e.g. petrol, alcohol etc.) to clean the boiler or any of its parts. Do not use paint thinners to clean the casing or any painted or plastic parts of the boiler. Use only soapy water to clean the boiler casing. 6.2 Extraordinary maintenance Extraordinary maintenance involves actions designed to restore the functioning of the boiler to its design specifications and to ensure conformity to legal requirements after a failure or malfunction. These actions can be: Replacement of parts Repairs Reconditioning of parts. These actions generally require special tools and equipment. 24 Scheduled maintenance normally consists of the following operations. Remove encrustations from the burner. Remove encrustations from the heat exchangers. Check and clean the flue pipes. Check the efficiency of the external casing. Check the ignition, normal functioning and shutdown of the boiler in DHW and CH modes. Check the tightness of the gas and water pipe joints. Check gas consumption at maximum and minimum power. Check the position of the ignition electrode and flame detection sensor. Check the gas failure safety system.

7 OPTIONAL ACCESSORIES Wall-mounted weekly timer thermostat (fig. 7.1) (part number 1100279). Fig. 7.1 Pump or valve controlled multizone central heating kit with total shut-down function (fig. 7.2) (part number 696439). Fig. 7.2 RO120 storage cylinder (fig. 7.3) (part number 696339). 25 Fig. 7.3 High head pump (fig. 7.4) (part number 1100269). Fig. 7.4

INSTALLATION MANUAL 26 8 NOVELLA BOILERS: MODULAR CONFIGURATION 8.1 Configurations Special kits are available to enable Novella boilers to be installed in modular systems (i.e. in cascades) (fig. 8.1). The modular configurations listed in the following table can be formed using the kits specified. Total power (kw) System composition Flue kit 122 2 x Novella 55 rai 695149 141 2 x Novella 64 rai 695149 158 2 x Novella 71 rai 695159 183 3 x Novella 55 rai 695149+695169 211 3 x Novella 64 rai 695149+695169 237 3 x Novella 71 rai 695159+695179 Figure 8.2 provides a possible schematic for the connection of two Novella boilers in a system that only provides central heating (fig. 8.2). This configuration provides a total heat output equivalent to the sum of the heat outputs of its two Novella boilers. The functioning of the system can be controlled (modulated) from the control panel. T3 QC T5 Fig. 8.1 C1 C2 V1 V2 P1 C1, C2 Novella boilers V1, V2 3-way deviator valves P1 CH pump T3 Outdoor temperature sensor T5 CH flow temperature probe QC Control panel Fig. 8.2

Total heat output can be increased by adding a third Novella boiler to the modular installation. Domestic hot water can also be generated by adding a storage cylinder. Hot water production is also controlled from the control panel (QC). Figure 8.3 illustrates a modular installation comprising three Novella boilers, complete with DHW circuit. T3 QC T5 V4 T4 P2 C1 C2 C3 BO V1 V2 V3 FI P1 P2 Storage cylinder pump T5 CH flow temperature sensor BO Storage cylinder QC Control panel FI Filter T3 Outdoor temperature sensor P1 CH pump T4 Storage cylinder temperature sensor C1, C2, C3 Novella boilers V1, V2, V3, V4 3-way deviator valves Fig. 8.3 27 8.2 Overall dimensions Modular connection of two Novella boilers (fig. 8.4). Fig. 8.4 DESCRIPTION 2-boiler system NOVELLA 55 RAI NOVELLA 64 RAI 2-boiler system NOVELLA 71 RAI A (mm) 1930 2130 B Ø (mm) 260 300 C (mm) 535 510

INSTALLATION MANUAL 28 Modular connection of three Novella boilers (fig. 8.5). DESCRIZIONE 3-boiler system NOVELLA 55 RAI NOVELLA 64 RAI Fig. 8.5 3-boiler system NOVELLA 71 RAI A (mm) 1915 2105 B Ø (mm) 300 350 C (mm) 515 505

Cod. 20048748-02/12 Ed. 0 Via Risorgimento, 13-23900 Lecco (LC) Servizio Clienti 199.13.31.31* Assistenza Tecnica Numero Unico 199.12.12.12* www.berettaclima.it Beretta is constantly improving its products and therefore reserves the right to modify the characteristics and specifications of the appliance described in this manual at any time and without prior notice. The contents of this manual are not contractually binding on the manufacturer.