Beretta POWER PLUS Installation Instruction
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Beretta POWER PLUS Installation Instruction

Wall-hung condensing boiler
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WALL-HUNG
POWER PLUS
CONDENSING
BOILER
INSTALLATION INSTRUCTION

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  • Page 1 WALL-HUNG POWER PLUS CONDENSING BOILER INSTALLATION INSTRUCTION...
  • Page 2 • Low Voltage Directive 73/23/EEC. • EN 677 standard on condensing boilers. 0085 POWER PLUS 50 M 20019155 POWER PLUS 100 M 20019200 POWER PLUS 100 S 20019309 POWER PLUS 100 M DEP 20019201 POWER PLUS 100 S DEP 20019319...
  • Page 3 Dear Customer, congratulations on your purchase of a POWER PLUS Boiler. This appliance ensures maximum comfort for an extended period, with high reliability, efficiency, quality and safety. The purpose of this manual is to provide all the information that we feel is necessary for the correct and simple installation of the boiler and must be preserved and made available as and when reque- sted to ensure correct installation, operation and maintenance.

  • Page 4: Table Of Contents

    Contents GENERAL SAFETY DEVICES TECHNICAL pag. 5 Starting for the first time pag. 39 DESCRIPTION OF THE APPLIANCE Checks during and after first start-up “ Description “ Setting the functional parameters “ Safety devices “ Setting the central heating parameters “...

  • Page 5: General Safety Devices

    General Safety Devices - if the boiler is not planned to be used for a The boilers produced in our factory are built with long period, he/she should call in the Technical care down to the last component to protect both Assistance Service to perform the following ope- the user and installer from eventual accidents.

  • Page 6: Description

    (for setting control parameters and displaying temperatures and system errors). Safety Devices The POWER PLUS Boiler is fitted with the following safety devices, installed on each heating unit: The activation of the safety devices indicates a Safety thermostat with automatic reset, activated if the potentially dangerous malfunction on the boiler;...

  • Page 7: Identification

    Identification The boilers can be identified by the: - Packaging label This shows the code, the serial number and the barcode. - Rating plate This shows the technical and perfor- mance specifications. Models 50 M 100 M 100 M DEP Models 100 S 100 S DEP...

  • Page 8: Structure

    Structure POWER PLUS 50 M POWER PLUS 100 M - 100 M DEP 100 S - 100 S DEP 12 16 12 15 1 - Fan 13 - Central heating return inlet 2 - Combustion air intake fitting 14 - Central heating flow outlet...

  • Page 9: Technical Specifications

    Technical Specifications POWER PLUS DESCRIPTION 50 M 100 M 100 S 100 M DEP 100 S DEP Fuel G20 - G30 - G31 Appliance category II2H3+ Type of appliance B23 - C63 - C63x Heat input ref. HHV (min - max)

  • Page 10: Water Circuit

    Water-side pressure drop in the boiler The POWER PLUS Boiler does not come with a pump, which must be installed in the system. When sizing the pump, refer to the water-side pressure drop in the boiler, as shown in the figure below.

  • Page 11: Positioning The Probes

    CENTRAL HEATING RETURN PROBE Pumps POWER PLUS Boiler does not come with a pump, which must be installed in the system. When choosing the pump, refer to the following system diagrams. Confi guration with distribution pumps Boiler discharge head: 7 mWC...
  • Page 12 Confi guration with injection pumps PB - DHW pump SZ1 - Probe in zone 1 Boiler discharge head: 6 mWC PZ1 - Pump in zone 1 SZ2 - Probe in zone 2 Boiler fl ow-rate: 2 m /h for each pump. (high temperature) SB - DHW probe Recommended ijection pump.
  • Page 13 Injection pump FLOW-RATE (m /h)

  • Page 14: Wiring Diagrams

    Wiring Diagrams The control panel on POWER PLUS models 50 M, 100 M and 100 M DEP contains one master board and one or two slave boards, depending on the output of the boiler. Models 100 S and 100 S DEP contain just two slave boards. If connecting a series of boilers in cascading, the master board on the POWER PLUS 50 M, 100 M or 100 M DEP manages all the boards on the POWER PLUS 100 S or 100 S DEP boilers via BUS.
  • Page 15 The pumps should be connected by installing suitable contactors with manual emergency operation. parte 2 to main earth pole to main earth pole EA/ER EA/ER Earth Earth Earth Fuse 4A Earth Line Line Neutral Neutral Gas valve Safety thermostat Diff. pressure switch SLAVE 1 SLAVE 2 Blower (+)
  • Page 16 POWER PLUS 100 S - 100 S DEP part 1 Main earth pole 230V~50Hz Earth Neutral Line Joint with sheath to main earth pole EA/ER Earth Earth Earth Fuse 4A Line Neutral Gas valve Safety thermostat Diff. pressure switch SLAVE 1...
  • Page 17 part 2 - Gas valve - Safety thermostat - Water differential pressure switch - Outlet probe - Return probe - Flue gas probe EA/ER - Ignition/detection electrode - Cable for connection to two-way valve or injection pump (accessories) - Main boiler switch - FIRST heating unit switch - SECOND heating unit switch J10/J17 - Microswitches for setting the address (see page 54)

  • Page 18: Control Panels

    1 - FIRST heating unit switch 12 13 14 2 - Button for selecting the operating mode 3 - Reset button (Master) POWER PLUS 100 M - 100 M DEP 4 - Boiler lockout signal 5 - Button for selecting the parameters 6 - Display...

  • Page 19: User Interface

    User Interface The buttons on the POWER PLUS 50 M, 100 M and 100 M DEP control panel have different functions in different modes. For example, the combination of two buttons corresponds to one specific function. Alternatively, a function can be activated by pressing the button briefly or by holding it for around 5 seconds.

  • Page 20: Display Mode

    DISPLAY MODE The red LED (see ref. 5 on page 18) comes on in the event of faults that cause the permanent lockout of a heating unit (normal operation is reset only by pressing the Master or Slave reset button). The 3 digits with seven segments display the status of the system: Status of the system Display...

  • Page 21: Setting The User Parameters

    Value displayed Display Operating status of the mixing valve E.g.: closing, opening, standby Operating status of the main pump E.g.: pump not working, pump working Operating status of the DHW pump E.g.: pump not working, pump working Operating status of the secondary pump E.g.: pump not working, pump working To exit the display of the values, press the “OK”...

  • Page 22: Monitor Mode

    Procedure Display Press “Set/esc” Press “ ” to change the set point to the desired value. E.g.: 40°C. Press “OK” to save the new value After 3 seconds Display mode resumes, with the new value set. If after having pressed “Set/esc” no change is made for 10 seconds (because the desired value is already set), the operation of the board returns to Readout mode.

  • Page 23: Installer Programming Mode

    Value Display Fan PWM signal (%). If PWM = 100%, this corresponds to 99 on the display. Es: 66 % Pressure switch open/closed E.g.: contact open Pump or motorised valve on the individual unit on/off E.g.: Pump ON E.g.: Pump OFF Maximum ionisation current (range from 0 to 99) at first attempt E.g.: maximum ionisation current 80 Hours of boiler functioning (from 0 to 9999 hours)

  • Page 24: Test Mode

    TEST MODE In Test mode, a high temperature heating demand can be generated corresponding to maximum output and minimum output. All the system fans must be on. If the installer switches off some of the Slaves, the others, connected to the Master, must continue operating.

  • Page 25: Receiving The Product Pag

    RECEIVING THE PRODUCT The POWER PLUS Boiler is supplied in a single packa- ge protected by a cardboard box. The following material is supplied with the boiler: - Installation and operation manual - Warranty certificate - Water pressure test certificate...

  • Page 26: Handling

    Room where the Boiler is Installed The POWER PLUS boiler must be installed in a dedicated boiler room, with adequately sized vents, in compliance with applicable laws and standards. If comburent air is drawn from outside the boiler room (using accessories code 1102439 and 1102449), the Powerplus boiler functions as a sealed (type C) appliance.

  • Page 27: Installation In Old Systems Or Systems To Be Upgraded

    Installation In Old Systems Or Systems To Be Upgraded Where Boilers are installed in old systems or systems to be upgraded, check that: - The flue is suitable for the temperature of the products of combustion with condensing operation, calculated and manufactured according to the standards, as strai- ght as possible, airtight, insulated and not blocked or choked.

  • Page 28: Installing The Boiler

    Installing the Boiler The POWER PLUS Boiler must be secured to a solid brick wall using the bracket (1). For installation: - Position the bracket (1) on the wall at a height of around 200 cm from the ground, using a spirit level to...
  • Page 29 CLEANING THE SYSTEM This preliminary operation is required when installing the heat generator in pre-existing systems, and is also recommen- ded in new systems, so as to remove any scale, impurities, processing residues etc. Power Flushing is recommended for system cleaning. To clean the system, if the old heat generator is still If the old heat generator is not installed or not available, installed in the system, proceed as follows:...

  • Page 30: Fuel Connections

    Fuel Connections The POWER PLUS Boiler must be connected to the natural gas or LPG supply in compliance with the rele- vant standards in force. When installation is completed, check that the joints are Before making the connections, check that: all tight, as required by the installation standards.
  • Page 31 MAXIMUM LENGTH OF THE PIPES model 50 M The maximum equivalent length of the sum of the 50 mm intake pipes and flues is 30 metres, with a pressure drop of 2 metres for each 90° bend. Installation of a single boiler with flue passing inside a compartment (open flue operation).
  • Page 32 PREPARING THE CONDENSATE DRAIN The condensate produced by the POWER PLUS boiler during normal operation must be drained at atmospheric pressure, i.e. by dripping into a siphoned drain system. This should be installed as follows: - Install a condensate collection tank at the condensate drain.

  • Page 33: Electrical Connections

    Electrical Connections The POWER PLUS 50 M, 100 M and 100 M DEP boilers leave the factory completely wired, with the power cable already connected, and only require the connection of the room thermostats, the outside probe and the pumps used, to the cor- responding terminals.
  • Page 34 - Identify the terminal block (5) and make the connec- tions, as in the diagram shown below.. TERMINAL BLOCK INSIDE THE MASTER CONTROL PANEL Probe in zone 1, PB (*) high temperature DHW pump PZ1 (*) Storage heater probe High Temperature system pump PZ2 (*) Loop pump or...

  • Page 35: Installing The Outside Probe

    Installing the Outside Probe The correct positioning of the outside probe is fundamental for the correct operation of the climate control function. The probe must be installed outside of the building being heated, at a height of around 2/3 of the wall facing NORTH or NORTH-WEST, and away from flues, doors, windows and areas exposed to direct sunlight.

  • Page 36: Filling And Emptying The Systems

    Filling and Emptying the Systems The POWER PLUS Boiler is not fitted with a filling valve, which must be installed on the system return. FILLING - Open the valves (1) installed on the boiler water fittings; - Open the caps on the automatic vent valve/valves (2) two or three turns;...
  • Page 37 EMPTYING Before starting to empty the system, disconnect the power supply by moving the main system switch to "off". Emptying the BOILER - Close the valves (1) - Connect a plastic hose to the drain cock (4), on each heating unit, and open the cock Before opening the drain cock (4), protect the electri- cal devices underneath against water spillage.

  • Page 38: Preparing For First Start-Up

    Preparing for First Start-up Before starting the system and running the functional tests on the POWER PLUS Boiler, check that: - The fuel valve and valves in the central heating system are open; - The type of gas and the supply pressure are correct for the boiler;...

  • Page 39: Starting For The First Time

    Starting for the First Time - Move the main system switch to "on"; - Move the main switch (1) on the boiler and the switches (2) on each heating unit to "on". The green SLAVE power supply signal (3) flashes. The boiler performs a self-diagnosis cycle, after which it will enter DISPLAY mode.
  • Page 40 (see the paragraph "Setting the temperature controller"). These settings must only be performed by BERETTA or a suitably qualified person. If the boiler is connected to a storage heater, set parameter 6 (pre-set to 0=no DHW service).

  • Page 41: Checks During And After First Start-Up

    (see ERROR MODE on page 24 and the "Fault codes" paragraph on page 56). Checks During and After First Start-up When ignition is complete, check that the POWER PLUS boiler correctly: - Starts and stops, closing the contacts on the zone ther- mostats;...
  • Page 42 After a few minutes of continuous operation controlled by the room thermostat, the adhesives and the processing residues will have evaporated, and the following checks can be completed: - check the gas supply pressure; - check combustion, CHECKING THE GAS SUPPLY PRESSURE - Move the main system switch to "off";...
  • Page 43 In TEST mode, a high temperature heating demand at maximum output can be generated. To do this: - Press the “Set/esc” and “+” buttons together for 5 seconds; - Start the boiler by adjusting the room thermostat. The boiler will operate at maximum output showing "H"...
  • Page 44 02 = natural gas and L>15 m 03 = LPG and L<15 m 04 = LPG and L>15 m. The POWER PLUS boilers are supplied for operation on G20 (natural gas), with a flue L<15m (parameter 36=01). Once the checks are complete, replace the front panel and secure it using the same screws.

  • Page 45: Setting The Functional Parameters

    Setting the Functional Parameters The functions of the central heating high temperature and low temperature circuits and the DHW circuits can be set based on the system requirements, by setting the functional parameters. The first three parameters are accessible at a user level, while the remaining parameters require the password to be entered ("22", see page 23).
  • Page 46 2 Setpoint_T_CH_Low Set point in the low temperature circuit (parameter 3) If the operating mode is set to "fixed set point" (par. 22=CH_type_low=0), this is the objective temperature. If the operating mode is set to "climate control" (par. 22=1), this is the maximum objective temperature for the mini- mum outside temperature (T_out_min=par.

  • Page 47: Setting The Domestic Hot Water Parameters

    Setting the Domestic Hot Water Parameters The following functions can be set for the domestic hot water circuit: 1 Setpoint_DHW Domestic hot water set point (parameter 2) This is the temperature value for the production of domestic hot water. The maximum limit is set by par. 8 (T_DHW_limit, pre-set to 60°C). Pre-set to 50°C.

  • Page 48: Setting The Temperature Controller

    Setting the Temperature Controller 1 Attenuation_High Attenuation function for the HIGH TEMPERATURE circuit (parameter 21) Two cases are possible: - Operation with fixed set point, Par. 14=0 - Operation with climate control Par. 14=1. OPERATION WITH FIXED SET POINT, PAR. 14=0 With attenuation in the high temperature circuit disabled, Par21=0, when the thermostat in the high temperature circuit closes, the heating demand is signalled.
  • Page 49 2 Attenuation_Low Attenuation function for the LOW TEMPERATURE circuit (parameter 25). This paragraph is similar to the previous one, however in this case referred to the low temperature circuit. Two cases are possible: - Operation with fixed set point, Par. 22=0 - Operation with climate control Par.
  • Page 50 3 T_out_correct Outside temperature correction (parameter 39) Normally the value displayed is the value read by the micro-controller, plus or minus a correction value (T displayed = T read by the probe +/- correction). The outside temperature value read can be corrected by changing the value of parameter 39, (the limit allowed for the correction is +/- 30 °C).
  • Page 51 Disconnect the power supply from the system, unplug the BUS and connect the PC interface. The output of the bur- ners can be sent directly to the Slave boards using the PC. In the event of faults, contact BERETTA or a suitably qualified person.
  • Page 52 Managing the heating demand in the high temperature circuit by analogue input (Par. 14=2 or 3) The room thermostat in the high temperature circuit is ignored for the heating demand, and the input signal is used to calculate the output or the system set point. There is just one analogue input (see terminals 13-14 on the wiring diagram on page 34) on the Master board and this can also be used for the low temperature circuit (Par.22).
  • Page 53 MANAGEMENT OF THE MIXING VALVE The mixing valve is controlled by the following parameters: Mix_valve_step_open_time: Par.28 pre-set to 5s Mix_valve_step_close_time: Par.29 pre-set to 7s Mix_valve_interval_time: Par.30 pre-set to 5s Mix_valve_p_hyst: Par.31 pre-set to 2°C Mix_valve_still_hyst: Par.32 pre-set to 2°C Before opening or closing, the valve waits the time set for Par.30.

  • Page 54: Setting The Addresses For Cascading Configurations

    Setting the Addresses for Cascading Configurations The microswitches on the slave boards are factory-set so as to interface a master boiler (50 M, 100 M or 100 M DEP) to a slave boiler (100 S or 100 S DEP). If further slave boilers need to be connected, only the microswitches on these boilers will need to be reset.
  • Page 55 Example configuration of a set of 7 burners in cascading If installing a set of seven slave generators, there are two blocks: the first made up of four generators, and the second of three. Therefore, two blocks need to be configured, with address 1 and 2 respectively, and the generators belonging to the first block must have address 1, 2, 3 and 4, and those belonging to the second block address 1, 2 and 3.

  • Page 56: Fault Codes

    Fault Codes ERRORS ON THE MASTER BOARD The following tables provide a description of the errors that may occur on the Master board. The errors can be divided into two groups: - Type A errors, which can only be deactivated by pressing RESET (see ref. 3 on page 18). - Type E errors, which are deactivated when the causes are no longer present.
  • Page 57 N° N° on PC Cause Checks and solutions Internal error Replace the slave board Internal error Replace the slave board Internal error Replace the slave board 50Hz error The mains frequency is not 50Hz Internal error Replace the slave board Internal software error Press the reset button Internal error...

  • Page 58: List Of Parameters

    List of Parameters No. Name lower upper default Description limit limit setting USER parameters SetPoint_ch_high Par. 17 °C If Par14=0 this is the high temperature circuit set point. If Par14=1 this is the maximum temperature in the high temperature circuit SetPoint_DHW Par.
  • Page 59 No. Name lower upper default Description limit limit settinglimit limit setting 26 CH_low_hyst_on °C Start hysteresis in low circuit calculated on the mixer outlet temp 27 CH_low_hyst_off °C Stop hysteresis in low circuit calculated on the mixer outlet temp 28 Mix_valve_step_ open_time 0 For each step the valve opens 1/2 of the set value 29 Mix_valve_step_close_time 0...

  • Page 60: Conversion From One Type Of Gas To The Other

    Conversion from One Type of Gas to the Other The conversion must only be carried out by The POWER PLUS Boiler is supplied for operation on BERETTA or personnel authorised by BERETTA, G20 (natural gas). However, it can be converted for even when the boiler is already installed.
  • Page 61 - Locate the gas jet and seal. If the system is methane fuelled, there is no diaphragm. - Replace the calibrated diaphragm fitted on the gas valve with the diaphragm (4) supplied inside the kit, mark “6.5”. Only if the boiler is supplied by a mixture of gases that causes ignition problems, use the other diaphragm (5) marked “6.75”.

  • Page 62: Adjustments

    Adjustments The adjustments at maximum and minimum The POWER PLUS Boiler is supplied for operation on output must be carried out in the sequence G20 (natural gas), as indicated on the rating plate, and described, and only by BERETTA or personnel has already been adjusted in the factory by the manu- authorised by BERETTA.

  • Page 63: Temporary Shutdown

    Temporary Shutdown In the event of temporary absence over the weekend, The frost protection function has two levels: brief trips, etc. proceed as follows: - the first starts the pump if the manifold temperature ≥ 5°C, or alternatively, when - Set the room thermostats to around 10°C CH_type=1 and the outside probe is connected;...

  • Page 64: Servicing

    It ensures reduced consumption and pollu- ting emissions and maintains the reliability of the pro- duct over time. The appliance can be serviced BERETTA or personnel authorised by BERETTA. Analysis of combustion, performed before starting ser- vicing, provides useful information on the operations to be performed.
  • Page 65 Removing the front panel, accessing the control panel and the inside of the boiler - Unscrew the fastening screws (1) on the front panel - Pull the base of the panel (2) outwards and then upwar- ds to release it from the frame and then remove it - Turn the control panel (3) 90°C and take out the four screws (4) so as to remove the rear cover.
  • Page 66 Dismantling the Master and Slave boards - Remove the panel front and access the inside of the control panel (see the steps described on the previous page). - Remove the screws (V) and then the cover from the Master board. - Repeat the same operation to remove the cover (7) from the first Slave board and (8) any second Slave board.
  • Page 67 Dismantling and cleaning the burner and the exchanger - Remove the front and top panel of the boiler (see the operations described on page 65). - Remove the wiring (5) from the fan (6) - Unscrew the two screws (8) that fasten the fan (6) to the air conveyor (9) - Unscrew the four screws (10) that fasten the fan assembly (6) to the exchanger, using a 10 mm socket...
  • Page 68 Cleaning the drain trap and condensate drain - Remove the front and top panel of the boiler (see the operations described on page 65) and identify the condensate drain trap (14) - Remove the safety pin (15), remove the corrugated condensate drain pipe, remove the drain trap and dismantle it, using the two screw caps (16).

  • Page 69: Troubleshooting

    TROUBLESHOOTING CAUSE SOLUTION PROBLEM Check the tightness of the joints Smell of gas Gas supply circuit and that the pressure test points are closed Check: Smell of unburned gas Flue gas circuit - The tightness of the joints - The absence of obstructions - The quality of combustion Irregular combustion Burner gas pressure...
  • Page 70 CAUSE SOLUTION PROBLEM Check: The boiler doesn’t start No power supply - electrical connections (the display is blank) - fuse The boiler does not reach the Boiler body dirty Clean combustion chamber operating temperature Insufficient burner flow-rate Check burner adjustment Boiler controller Check correct operation Check set temperature...
  • Page 72 Tel. 199.13.31.31 - Fax 0341-368.071 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.

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